York ZE036 User Manual

R-410A
ZE SERIES
3 - 6 Ton
60 Hertz
5742637-YIM-D-0620
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 ZE036-060). 15
Typical Cool/Heat Control Wiring (Smart Equipment™ ZE036-
072) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Field Installed Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 35
Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . .36
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 50
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Field Installed Electric Heating Sequence Of Operations . . . . 52
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 54
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 57
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 58
Smart Equipment™ Control Board Navigation Components . . . . 66
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LIST OF TABLES
1 ZE036-072 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZE036-072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZE036-072 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 8
4 ZE036-072 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 ZE036-072 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Electrical data: single-phase gas heat, belt drive . . . . . . . . . 29
9 ZE036-072 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 32
11 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 33
13 Smart Equipment™ Economizer Board Details . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
15 ZE Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45
16 ZE Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 46
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48
19 Power Exhaust Specifications. . . . . . . . . . . . . . . . . . . . . . . . 48
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53
23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 54
24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 54
25 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56
26 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
27 ZE036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
28 ZE048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
29 ZE060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
30 ZE072 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
31 Simplicity Lite Unit Control Board Flash Codes . . . . . . . . . . 66
32 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66
33 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 67
34 Cable for FC Buses and SA Buses in Order of Preference . 72
LIST OF FIGURES
1 ZE036-072 Component Location . . . . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZE036-072 Cooling Only Front View Physical Dimensions . . 9
6 ZE036-072 Cooling Only/Gas Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 ZE036-072 Fixed Outdoor Air Motorized Damper Rain Hood
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZE036-072 Disconnect Location . . . . . . . . . . . . . . . . . . . . . 10
9 ZE036-072 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 11
10 ZE036-072 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13
13 Typical Field Power and Simplicity Lite Control Wiring . . . .15
14 Typical Smart Equipment™ Control Wiring . . . . . . . . . . . . . 16
15 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
16 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
17 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 35
18 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . 35
19 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38
20 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
21 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
22 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 49
23 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
24 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 55
25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 56
26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 66
28 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 67

York ZE036 Specifications

General

Category	Air Conditioner
Cooling Capacity	3.6 kW
Refrigerant	R410A
Model	ZE036
Power Supply	220-240V, 50Hz
Noise Level (Outdoor Unit)	52 dB

Summary

Rigging And Handling

Clearances

Compressors

Power And Control Wiring

Typical Field Power and Control Wiring

Typical Power Wiring

Typical Cool/Heat Control Wiring (Simplicity Lite ZE036-060)

Typical Cool/Heat Control Wiring (Smart Equipment™™ ZE036-072)

Field Installed Electric Heat

Gas Piping

Gas Connection

Smart Equipment™™ Economizer Sequences

Free Cooling Operation

Phasing

Belt Tension

CFM Static Pressure and Power-Altitude and Temperature Corrections

Altitude/Temperature Correction Factors

Drive Selection

Checking Supply Air CFM

Cooling Operation Errors

High-Pressure Limit Switch

Error handling for high-pressure limit switch trips.

Low-Pressure Limit Switch

Error handling for low-pressure limit switch trips.

Evaporator Low Limit (Smart Equipment™™ Control)

Error handling for evaporator low limit sensor trips.

Field Installed Electric Heating Sequence Of Operations

Electric Heat Operation Errors

Error handling for electric heat operation errors.

Temperature Limit Switch (TLS)

Function and operation of the temperature limit switch.

Gas Heating Sequence Of Operations

Gas Heat Operation Errors

Error handling for gas heat operation faults.

Temperature Limits

Location and function of primary and auxiliary temperature limits.

Flash Codes or Error Messages

Start-up (Gas Heat)

Pre-start Check List

Post-Start Check List (Gas)

Checking Gas Input

Natural Gas

Start Up For Units Equipped for FER

Troubleshooting (Simplicity Lite Only)

Blower Motor Not Energizing

Troubleshooting steps when the blower motor doesn't start during cooling.

Compressor Not Energizing

Troubleshooting steps when the compressor doesn't start during cooling.

Gas Heat Troubleshooting Guide

Ignition Control Board

Troubleshooting the ignition control board and its connections.

Centrifugal Switch

Troubleshooting the centrifugal switch for faults.

Primary or Aux Temperature Limit

Troubleshooting temperature limits in gas heat systems.

Roll-out Switch

Troubleshooting the roll-out switch for overheating issues.

Symptomatic Troubleshooting

Simplicity Lite Unit Flash Codes

Simplicity Lite Unit Control Board Flash Codes

Start-Up Sheet

SAFETY WARNINGS

Operating Measurements - Air Flow

Final Adjusted Supply Air CFM

ELECTRICAL DATA

OPERATING MEASUREMENTS - COOLING

REFRIGERANT SAFETIES

Actions to prove refrigerant safety system operation.

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

FINAL - INSPECTION