York ZD-04 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-04 Specifications

General

Cooling Capacity	12000 BTU/h
Refrigerant	R410A
Type	Split System
Power Supply	220-240V, 50Hz
Operating Temperature Range (Cooling)	18°C to 43°C

Summary

General

Safety Considerations

Provides safety alert symbols and explains signal words like DANGER, WARNING, and CAUTION.

Installation

Installation Safety Information

Provides critical safety instructions for appliance installation, including outdoor use and gas connections.

Location

Guidelines for selecting a suitable outdoor location, considering air supply and mounting.

Clearances

Specifies required clearances for operation, service, and combustion air in accordance with codes.

Rigging And Handling

Power And Control Wiring

Thermostat Wiring

Guidance on thermostat location and wiring, including wire size and maximum length.

Typical Field Power and Control Wiring

Typical Power Wiring

Typical Cool/Heat Control Wiring (Simplicity SE ZD-03 Thru -05)

Wiring diagram for connecting thermostat to the Unit Control Board for Simplicity SE.

Typical Cool/Heat Control Wiring (Simplicity Lite ZD-03 Thru -05)

Wiring diagram for connecting thermostat to the Unit Control Board for Simplicity Lite.

Optional Electric Heat

Optional Gas Heat

Description of gas-fired heaters, their materials, and factory shipping configuration.

Gas Piping

Gas Connection

Vent And Combustion Air Hoods

Options/Accessories

Electric Heat

Economizer/Motorized Damper and Rain Hood

Instructions for assembling economizer rain hoods and details on factory-mounted components.

Economizer Setup And Configuration

Describes the process for setting up and configuring the JADE Economizer module for the installed system.

Economizer And Power Exhaust Set Point Adjustments

Procedure to adjust economizer control module settings and power exhaust set points.

Enthalpy Settings

Free Cooling

Describes four free cooling options: dry bulb, single enthalpy, dual enthalpy, and auto changeover.

Dry Bulb Changeover

Single Enthalpy Changeover

Dual Enthalpy Changeover

Operation

Economizer With Dual Enthalpy Sensors

Describes economizer operation with dual enthalpy sensors for maximum efficiency.

Cooling Sequence Of Operation

Details the cooling operation sequence for Simplicity Lite and SE control boards.

Economizer With Power Exhaust

No Outdoor Air Options

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

Explains economizer operation with single enthalpy or dry bulb sensors, including damper modulation.

Cooling Operation Errors

High-Pressure Limit Switch

Details UCB response to high-pressure limit switch openings and potential lockouts.

Low-Pressure Limit Switch

Explains UCB response to low-pressure limit switch failures and potential lockouts.

Freezestat (Simplicity Lite Control)

Describes UCB response to freezestat openings in Simplicity Lite controls, including lockouts.

Evaporator Low Limit (Simplicity SE Control)

Details UCB response to evaporator low limit sensor trips in Simplicity SE controls, including lockouts.

Low Ambient Cooling (Simplicity Lite Control)

Explains low ambient cooling mode operation for Simplicity Lite controls, including compressor cycling.

Low Ambient Cooling (Simplicity SE Control)

Describes low ambient cooling mode operation for Simplicity SE controls, including compressor cycling.

Drive Selection

Checking Supply Air CFM

Safety Controls

Compressor Protection

Explains compressor protection features like internal protectors and Anti-Short Cycle Delay (ASCD).

Temperature Limit Switch (TLS)

Explains the function of the temperature limit switch and its automatic reset feature.

Flash Codes or Error Messages

Describes how the UCB provides flash codes for system errors and messages for Simplicity SE.

Electric Heating Sequence Of Operations

Single-stage heating

Describes the sequence for single-stage electric heating operation, including sequencers and blower.

Two-stage heating

Explains the sequence for two-stage electric heating, including sequencers and contactors.

Electric Heat Operation Errors

Details errors related to electric heat, such as temperature limit issues and their UCB response.

Electric Heat Anticipator Setpoints

Gas Heating Sequence Of Operations

Gas Heat Operation Errors

Temperature Limits

Explains primary and auxiliary temperature limits, their function, and UCB responses to faults.

Flame Sense Circuit

Describes the flame sense circuit, its function, and troubleshooting for flame detection issues.

Symptomatic Troubleshooting

Start-up (Cooling)

Prestart Check List

Checklist of electrical and operational items before starting the unit for cooling.

Operating Instructions

Steps for setting thermostat and verifying operation during cooling startup.

Post Start Check List

Checks to perform after startup, including system pressures and temperature drops.

Start-up (Gas Heat)

Pre-start checklist for gas heating unit startup, including gas type and vent hoods.

Manifold Gas Pressure Adjustment

Operating Instructions

To Light Pilot And Main Burners

Post-Start Check List (Gas)

Checks to perform after gas heating startup, including leak checks and pressure verification.

Pilot Checkout

Checking Gas Input

Natural Gas

Adjustment Of Temperature Rise

Troubleshooting

Gas Heat Troubleshooting Guide

Flash Code Troubleshooting

Explains how to troubleshoot faults using flash codes and the UCB/ICB LEDs.

Ignition Control Board

Troubleshooting steps for the Ignition Control Board (ICB) based on LED status and wiring.

Primary or Aux Temperature Limit

Troubleshooting temperature limits, airflow issues, and UCB responses to limit faults.

Roll-out Switch

Details the roll-out switch, its causes for opening, and troubleshooting procedures.

Centrifugal Switch

Troubleshooting the centrifugal switch for the draft motor, including checking voltage and continuity.

Unexpected Flame Presence

Troubleshooting procedure for flame presence without a call for heat.

Pilot Flame Lockout

Explains pilot flame lockout conditions, causes, and troubleshooting steps for ignition issues.

Gas Valve Stuck Off or On

Troubleshooting steps for gas valve failures, including hard lockout conditions.

Flame Sense Circuit Failure

Troubleshooting internal hardware failures in the flame sense circuit, resulting in hard lockout.

Unit Flash Codes

LAST ERROR

TEST RESET

Fan On And Off Delays

Simplicity SE Control Board Navigation Components

SIMPLICITY™ SE (SMART EQUIPMENT) FIRMWARE VERSION 3. BASIC UNIT CONTROL BOARD NAVIGATION EXAMPLES:

Understanding the Local LCD

Commissioning

Step 3- After "ENTER" is pressed the various parameter sections appear...

Step 4- After toggling the joystick down two times "Clg" appears...

Step 6- By toggling down twice the screen reaches the "ClgOcc-SP" screen...

Start-Up Sheet

EQUIPMENT STARTUP

Instructions for completing startup using local LCD or Mobile Access Portal (MAP) Gateway.

SAFETY WARNINGS

DESIGN APPLICATION INFORMATION

Operating Measurements - Air Flow

OPERATING MEASUREMENTS - COOLING

REFRIGERANT SAFETIES

Checks for compressor rotation, high/low pressure safety, and refrigerant charge verification.

OPERATING MEASUREMENTS - GAS HEATING

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

Verify Proper Operation of Heating/Cooling Staging Controls

Verifies correct operation of heating/cooling staging controls and economizer stages.

Verify Proper Operation of the Variable Frequency Drive (If Required)

FINAL - INSPECTION

Final checks on control set points, option parameters, and access panel security.