York ZE060 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 ZE060 Specifications

General

Cooling Capacity	6.0 kW
Heating Capacity	6.5 kW
Refrigerant	R410A
Outdoor Unit Weight	42 kg
Power Supply	220-240V, 50Hz

Summary

General Information and Safety

Safety Considerations and Warnings

Alerts to potential injury, requires attention to signal words, and covers installation compliance, refrigerant handling, and fire/explosion hazards.

Installation Requirements and Precautions

General Installation Precautions

Includes CAUTIONs about code compliance and WARNINGs about improper installation and R-410A refrigerant.

Installation Details and Warnings

Installation Safety Information

Read instructions, ensure availability to consumer, and follow safety precautions and codes.

Installation Warnings and Cautions

Emphasizes strict compliance with codes and potential hazards from improper installation or R-410A refrigerant.

Filters, Wiring, and Disconnect Requirements

Power and Control Wiring Standards

Details wiring requirements, codes, grounding, and circuit protection for power and control connections.

Disconnect Requirements

Specifies the need for a disconnect, factory options, and cautions regarding mounting.

Electrical Connections and Thermostat Wiring

High-Leg Delta Power Supply Cautions

Power Wiring and Thermostat Wiring

Covers power wiring sizing, transformer tap adjustments, and control wire sizing/length for thermostats.

Typical Field Wiring Diagrams

Typical Power Wiring Diagram

Diagram illustrating typical field power wiring connections including contactors and disconnects.

Simplicity Lite Control Wiring Diagram

Wiring diagram for Simplicity Lite controls, showing thermostat and UCB connections.

Smart Equipment™ Control Wiring

Smart Equipment™ Control Wiring Diagram

Wiring diagram for Smart Equipment control, detailing thermostat and UCB connections.

Gas Piping and Connection Procedures

Gas Piping Sizing Guidelines

Guidelines for proper gas piping sizing based on flow rate, specific gravity, and length, referencing codes and tables.

Gas Connection Recommendations

Details gas piping recommendations, including drip legs, unions, pipe types, cleaning, and leak testing.

Gas System Safety and Venting

Gas System Safety Warnings

Emphasizes fire/explosion hazards, proper pipe dope for LP gas, and leak testing procedures.

Economizer Control Parameters and Sequences

Economizer Controller Menu Functions

Discusses conditional parameters, sensor presence, and function-specific menu items.

Smart Equipment™™ Economizer Sequences

Outlines economizer drivers like minimum position, free cooling, loading, and outdoor air supply.

Economizer Minimum Position Setting

Free Cooling Options Explained

Economizer Operation and Power Exhaust

Free Cooling Operation Details

Single Sensor Economizer Operation

Dual Enthalpy Economizer Operation

Economizer With Power Exhaust Integration

Airflow and Altitude Correction Factors

Altitude/Temperature Correction Table

Altitude and Temperature Correction Factor Examples

Altitude/Temperature Correction Factors

Checking Supply Air CFM

Supply Air CFM Measurement Procedure

Procedure for measuring supply air CFM using static pressure readings and blower performance data.

Airflow and Static Pressure Warning

Failure to properly adjust system airflow and static pressure can cause extensive system damage.

Operation Sequences

Cooling Sequence of Operation

No Outdoor Air Options Cooling

Single Sensor Economizer Cooling

Cooling Operation Errors and Low Ambient Cooling

High-Pressure Limit Switch Errors

Describes what happens when the high-pressure limit switch opens and lockout conditions.

Low-Pressure Limit Switch Errors

Details low-pressure limit switch monitoring and lockout conditions.

Freezestat and Evaporator Low Limit Errors

Explains freezestat operation and evaporator low limit sensor lockout conditions.

Low Ambient Cooling Modes

Cooling Safety Controls and Electric Heat Errors

Cooling Safety Control Monitoring

Lists safety controls monitored by the UCB for cooling, including pressure switches and freezestats.

Electric Heat Temperature Limit Errors

Describes errors related to the electric heat temperature limit and its impact on blower operation.

Temperature Limit Switch (TLS) Function

Details the location and function of the temperature limit switch in the electric heat compartment.

Electric Heat Limits and Gas Heating Sequences

Electric Heat Limit Setting Table

Gas Heating Sequence of Operations

Describes the step-by-step process for gas heating ignition, operation, and safety checks.

Gas Heating Controls and Setpoints

Gas Heating Control Monitoring

Details furnace shutdown conditions, auxiliary limits, and gas valve monitoring.

Gas Valve and Centrifugal Switch Functions

Explains the redundant gas valve operation and the function of the centrifugal switch.

Roll-out Switch and Pilot Flame Lockout

Describes the roll-out switch function and pilot flame lockout conditions.

Electric Heat Anticipator Setpoints

Gas Heat Start-up Procedures

Gas Heat Pre-start Checklist

Pre-start checks for gas type, vent hoods, and pilot/main burner lighting.

Gas Heat Operating Instructions

Gas Heat Post-Start Checklist

Checks after heating operation begins, including gas leaks, manifold pressure, and supply gas pressure.

Gas Burner Adjustments and Input Checks

Manifold Gas Pressure Adjustment

Instructions for adjusting manifold gas pressure using the regulator screws.

Proper Flame Adjustment Procedure

Checking Natural Gas Input

Procedure for checking natural gas input, measuring meter revolutions, and calculating consumption.

Troubleshooting - Simplicity Lite Controls

Compressor Not Energizing During Cooling

Troubleshooting steps if the compressor is not energizing but the blower is.

Blower Not Energizing During Cooling

Troubleshooting steps if the blower motor is not energizing during a cooling call.

Troubleshooting Continued - Control Logic

Compressor Lockouts and Economizer Wiring Issues

Explains compressor lockouts, ASCD, economizer wiring issues, and potential UCB faults.

Gas Heat Troubleshooting Guide

Ignition Control Board Troubleshooting

Troubleshooting steps for the ignition control board, including LED indicators, voltage checks, and wiring verification.

Centrifugal Switch Diagnosis

Procedure for diagnosing and resolving issues with the centrifugal switch on the draft motor.

Gas Heat Troubleshooting Continued

Pilot Flame Lockout Troubleshooting

Troubleshooting steps for pilot flame issues, including flame sensor adjustment and burner assembly checks.

Unexpected Flame Presence Troubleshooting

Troubleshooting steps for flame presence without a call for heat, involving gas valve and ICB checks.

Temperature Limit Issues

Details the function of temperature limits and troubleshooting steps for limit trips and furnace shutdowns.

Gas Valve Stuck Issues

Troubleshooting for gas valve issues, including hard lockouts and power reset procedures.

Flame Sense Circuit Failure Troubleshooting

Steps to take if the flame sense circuit fails, leading to a hard lockout.

Symptomatic Heating Troubleshooting

Troubleshooting common heating issues like blower or draft motor not operating.

Simplicity Lite Flash Codes and Troubleshooting

Simplicity Lite Flash Code Explanation

Explains Simplicity Lite flash codes for normal operation and errors, including LAST ERROR and TEST RESET functions.

Control Board Flash Codes and Navigation

Simplicity Lite UCB Flash Codes Table

Table listing Simplicity Lite UCB flash codes and their corresponding descriptions for troubleshooting.

Ignition Control Board Flash Codes Table

Table listing Ignition Control Board flash codes and their descriptions for fault identification.

Smart Equipment™ UCB Terminal Details Continued

Analog Input Sensor Connections

Heat Section Terminal Connections

Refrigerant Safety Switch and Overload Connections

Continues UCB connections for refrigerant circuit safety switches, including overload relays.

Input/Output Pin Connections

Cooling and Fan Output Connections

Refrigerant Circuit Safety Switch Connections

Explains UCB connections for refrigerant circuit high and low-pressure switches for compressors.

Start-Up Procedures and Warranty

Start-Up & Service Data Instruction

Covers general start-up procedures, warranty statements, and equipment startup using LCD or MAP Gateway.

Safety Warnings and Design Application Information

General Safety Warnings for Startup

General safety warnings about lethal voltages and moving parts during startup checks.

Design Application Information Capture

Operational Measurements and Final Inspection

Staging Controls Verification

Verifying proper operation of heating/cooling staging and variable frequency drive.

Final Inspection Checklist Items

Final checks on control set points, options, panel security, and saving backup files.