York ZF036 User Manual

R-410A
ZF SERIES
3 - 6.3 Ton
50 Hertz
5725848-XIM-A-0319
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation safety information . . . . . . . . . . . . . . . . . . . . . . . 7
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical cool/heat control wiring (Smart Equipment™ ZF036-
076) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power and control wiring. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Optional gas heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Gas piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
L.P. units, tanks, and piping . . . . . . . . . . . . . . . . . . . . . . . 14
Vent and combustion air hoods. . . . . . . . . . . . . . . . . . . . . 15
RRS economizer interface overview . . . . . . . . . . . . . . . . . 16
Smart Equipment™ economizer sequences. . . . . . . . . . . 16
Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Single enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . 17
Dual enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Free cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Jade Economizer interface overview . . . . . . . . . . . . . . . . 22
ZF036-076 unit weights. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Supply air blowers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Checking supply airflow rate . . . . . . . . . . . . . . . . . . . . . . . 35
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . 37
Electric heating sequence of operations . . . . . . . . . . . .
. . 39
Safety controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gas heating sequence of operation . . . . . . . . . . . . . . . . . 40
Gas heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flash codes or error messages. . . . . . . . . . . . . . . . . . . . . 41
Heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start-up (cooling). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Prestart checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Post start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shutting down the unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Start up (gas heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Post start checklist (gas) . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Manifold gas pressure adjustment . . . . . . . . . . . . . . . . . . 43
Pilot checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Burner instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Burner air shutter adjustment . . . . . . . . . . . . . . . . . . . . . . 43
Checking gas input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Adjustment of temperature rise. . . . . . . . . . . . . . . . . . . . . 44
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cooling troubleshooting guide. . . . . . . . . . . . . . . . . . . . . . 45
Gas heat troubleshooting guide . . . . . . . . . . . . . . . . . . . . 46
Flash code troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 47
Symptomatic troubleshooting . . . . . . . . . . . . . . . . . . . . . . 49
Unit flash codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fan on and off delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Navigation components for the Smart Equipment™ control
board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Typical wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Simplicity® Lite control board . . . . . . . . . . . . . . . . . . . . . . 58
Smart Equipment™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
LIST OF TABLES
1 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Electric heater supply air limitations . . . . . . . . . . . . . . . . 13
3 Gas heat application data . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Gas pipe sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Smart Equipment™ Economizer Board details . . . . . . . 19
6 Single enthalpy and dual enthalpy high limit curves. . . . 24
7 ZF036-076 imperial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8 ZF036-076 metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 ZF036-076 unit accessory weights . . . . . . . . . . . . . . . . . 25
10 ZF036-076 physical data. . . . . . . . . . . . . . . . . . . . . . . . . 26
11 Electrical data ZF036-076 . . . . . . . . . . . . . . . . . . . . . . . . 28
12 Electric heat correction factors . . . . . . . . . . . . . . . . . . . . 28
13 Voltage limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14 Utilities entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16 Supply air blower performance (3 and 4 ton direct drive) -
side duct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
17 Supply air blower performance (5 ton belt drive) - side duct
application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
18 Supply air blower performance (6.3 ton belt drive) - side duct
application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
19 Belt drive motor and drive data . . . . . . . . . . . . . . . . . . . . 35
20 Static resistances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
21 Limit control setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
22 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . 40
23 Limit control setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
24 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . 41
25 Gas rate - cubic feet per hour . . . . . . . . . . . . . . . . . . . . . 44
26 Simplicity Lite unit control board flash codes . . . . . . . . . 51
27 Ignition control board flash codes . . . . . . . . . . . . . . . . . . 51
28 Smart Equipment™ UCB details . . . . . . . . . . . . . . . . . . 52
29 Cable for FC buses and SA buses in order of preference 57

York ZF036 Specifications

General

Brand	York
Model	ZF036
Category	Air Conditioner
Language	English

Summary

General Information

Safety Considerations

Safety alerts, signal words (DANGER, WARNING, CAUTION), and general precautions.

Inspection

Checking for transit damage and reporting issues.

Installation Requirements

Installation Safety Information

General safety guidelines for installation procedures.

Limitations and Location

Installation constraints, codes, and site selection guidelines.

Rigging, Handling, and Clearances

Rigging and Handling

Procedures for safely moving and lifting the unit.

Clearances

Required space for operation and service.

System Connections

Condensate Drain

Proper installation of the condensate drain line.

Service Access

Locations of panels for accessing unit components.

Wiring Diagrams

Typical Power Wiring

Diagram for electrical power connections to the unit.

Typical Control Wiring (Simplicity Lite)

Diagram for control wiring with Simplicity Lite.

Power and Control Wiring

Typical Cool/Heat Control Wiring (Smart Equipment)

Wiring diagram for Smart Equipment control.

Gas System and Venting

Gas Piping

Sizing requirements and code compliance for gas piping.

Vent and Combustion Air Hoods

Installation instructions for vent and combustion air hoods.

Economizer System Overview

RRS Economizer Interface

Using the RRS economizer controls.

Free Cooling Operation

How free cooling functions and its types.

Operation Modes

Cooling Sequence of Operation

Step-by-step process for cooling activation.

Economizer Operation Modes

Different modes of economizer operation.

Cooling Operation Errors

High-Pressure Limit Switch

Safety control for high discharge pressure.

Low-Pressure Limit Switch

Safety control for low refrigerant pressure.

Evaporator Low Limit (Smart Equipment)

Safety control for low evaporator temperature.

Low Ambient Cooling

Operation in low ambient temperature conditions.

Safety Controls and Heating Sequences

Safety Controls

Monitoring of various safety inputs by the control board.

Electric Heating Sequence of Operations

How electric heating stages are activated.

Gas Heating Sequence of Operation

Heat Anticipator Setpoints

Proper setting of heat anticipators for efficient operation.

Start-Up Procedures

Start-Up (Cooling)

Procedures for initial cooling system startup.

Start Up (Gas Heat)

Procedures for initial gas heat system startup.

Troubleshooting Guides

Cooling Troubleshooting Guide

Step-by-step guide for resolving cooling system problems.

Gas Heat Troubleshooting Guide

Step-by-step guide for resolving gas heat system problems.

Flash Code Troubleshooting

Diagnosing issues based on unit flash codes.

Symptomatic Troubleshooting

Unit Flash Codes and Fan Delays

Explanation of flash codes and fan delay adjustments.

Smart Equipment™™ Control

Smart Equipment™™ Economizer Board Details

Pinouts and functions of the economizer board.

Smart Equipment™™ UCB Details

Description of UCB terminals and connections.

Typical Wiring Diagrams

Simplicity® Lite Control Board Wiring

Wiring diagram for Simplicity Lite board.

Smart Equipment™™ Control Wiring (Electric Heat)

Wiring diagram for Smart Equipment with electric heat.

Final Checks and Measurements

Safety Warnings

Critical safety warnings for all procedures.

Final - Inspection

Final checks and procedures before completion.