York ZE072 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 ZE072 Specifications

General

Cooling Capacity	7.2 kW
Refrigerant	R410A
Outdoor Unit Weight	42 kg
Type	Split System
Power Supply	220-240V, 50Hz

Summary

General

Safety Considerations and Warnings

Safety alert symbol, signal words (DANGER, WARNING, CAUTION), and hazard warnings.

Installation

Installation Safety Information

Read instructions, understand signals like DANGER, WARNING, CAUTION.

Installation Safety

Installation Hazards and Precautions

Cautions on codes, refrigerant, and warnings on improper installation.

Location

Rigging and Handling

Safety Warnings

Warnings regarding contaminated combustion air and rigging precautions.

Power And Control Wiring

Wiring Standards and Precautions

Conformance to codes, replacement wire, disconnects, and waterproof connectors.

Power and Thermostat Wiring

Typical Field Wiring Diagrams

Power Wiring Diagram

Simplicity Lite Control Wiring

Wiring diagram for Simplicity Lite control systems.

Smart Equipment™™ Control Wiring

Smart Equipment™™ Control Wiring Diagram

Wiring diagram for Smart Equipment™™ controls, including R~Occ Jumper.

Field Installed Electric Heat

Electric Heat Operation and Safety

Gas Piping

Gas Piping Sizing and Connections

Gas Piping Safety Warnings

Warnings regarding LP gas solvent properties and gas leak detection.

LP Gas Units and Venting

RRS Economizer Interface Overview

Smart Equipment™™ Economizer Sequences

Economizer Minimum Position and Free Cooling

Free Cooling Operation Modes

Dry bulb, single enthalpy, dual enthalpy, and auto modes for free cooling.

Thermostat Integration with Free Cooling

Economizer Controller Board

Analog Inputs

LEDs and Indicators

SA Bus Connections

Economizer Board Connections

Economizer Board Sensor Inputs

Temperature and Humidity Sensors

Air Quality and Pressure Sensors

Economizer Board Input Logic

Indoor Air Quality Sensor Operation

Unit Phasing and Belt Tension

Altitude and Temperature Corrections

Altitude Correction Examples

Drive Selection Process

Checking Supply Air CFM

Supply Air CFM Measurement Procedure

System Air Quantity Warning

Warning about potential system damage from improper air quantity adjustment.

Operation Sequences

Economizer Cooling Sequences

Operation with single/dual enthalpy, dry bulb, power exhaust, and dampers.

Cooling Operation Errors

Pressure and Freezestat Errors

High/low pressure limits, freezestat, and evaporator low limit errors.

Low Ambient Cooling Operation

Unit operation in low ambient conditions with Simplicity Lite or Smart Equipment.

Safety Control Monitoring

Monitoring of safety inputs for cooling system operation.

Electric Heat Operation Errors

Temperature Limit Errors

Safety Controls for Electric Heat

Field Installed Electric Heating Sequence Of Operations

Single-stage Electric Heat Operation

Operation for single-stage electric heat.

Two-stage Electric Heat Operation

Operation for two-stage electric heat.

Gas Heating Sequence Of Operations

Ignition Control Board Function

ICB function, checks, and troubleshooting.

Gas Heating Operation Errors

Errors monitored by ICB and UCB during furnace operation.

Temperature Limits in Gas Heating

Function of primary and auxiliary temperature limits.

Gas Heat Troubleshooting

Ignition and Flame Sensing Issues

Centrifugal switch, roll-out switch, pilot lockout, unexpected flame.

Pilot Flame Lockout and Temperature Limits

Issues with pilot flame, primary/aux limits, and roll-out switch.

Flame Presence, Gas Valve, and Flame Sense Errors

Troubleshooting unexpected flame, stuck gas valve, and flame sense failures.

Gas Valve and Flame Sense Errors

Gas valve stuck, flame sense circuit failure, and unexpected flame presence.

Symptomatic Troubleshooting (Blower/Draft Motor)

Troubleshooting blower and draft motor issues when heating.

Symptomatic Troubleshooting

Troubleshooting blower motor and draft motor issues.

Gas Heat Adjustments and Checks

Manifold Gas Pressure Adjustment

Adjusting gas pressure and checking flame appearance.

Pilot Checkout and Burner Service

Pilot flame adjustment, burner service, and air shutter adjustment.

Checking Gas Input

Measuring gas consumption rate for natural gas.

Gas Heat Performance and Start-up

Temperature Rise Adjustment

Ensuring temperature rise is within specified ranges.

FER Unit Start-up Procedures

Start-up for Direct Drive and Belt Drive FER units.

Fan Speed Adjustments

Adjusting fan speed commands via control board or MAP Gateway.

Troubleshooting (Simplicity Lite Only)

Blower Motor Not Energizing

Troubleshooting steps if blower motor doesn't start.

Economizer Wiring Issues

Checking Y1 OUT terminal wiring and economizer connections.

Compressor Not Operating

Troubleshooting steps if compressor doesn't start.

Compressor Lockout Conditions

Checking for lockouts due to pressure switches, ASCD, or programming.

Gas Heat Troubleshooting Guide

Ignition Control Board (ICB) Issues

ICB function, checks, and troubleshooting.

Centrifugal Switch Troubleshooting

Troubleshooting the centrifugal switch and draft motor.

Wiring and Installation Safety

Simplicity Lite Unit Flash Codes

Flash Code Identification

Error Code Navigation and Reset

Control Board Information

Simplicity Lite Control Board Codes

Ignition Control Board Codes

Smart Equipment™™ Control Navigation

Smart Equipment™™ Unit Control Board (UCB) Details

UCB Terminal Connections Overview

Thermostat Connection Terminals

Sensor and Input Connections

Heat and Fan Output Terminals

Refrigerant Circuit Safety Inputs (Continued)

UCB LED Indicators

Output and VFD Connections

Refrigerant Circuit Safety Inputs

Fan Overload and SA Bus Connections

Sensor Connection Terminals

User Interface Items

Communication Bus Connections

Start-Up Sheet Procedures

Warranty Statement

Equipment Startup Process

Safety Warnings

General Safety Practices

Observing industry standards and assessing potential dangers.

Electrical and Moving Part Hazards

Warnings about lethal voltages and exposed moving parts.

Operating Measurements - Air Flow

OPERATING MEASUREMENTS - COOLING

Refrigerant Safeties Verification

OPERATING MEASUREMENTS - GAS HEATING

Gas Heating Safety Checks

Temperature Rise Check

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

Final Inspection Procedure