York ZF048 - 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

Summary

General

Safety considerations

Alert symbol usage and signal word definitions (DANGER, WARNING, CAUTION).

Installation

Installation safety information

Instructions for safe installation, including gas leak testing and electrical safety.

Limitations

Installation must comply with codes; unit sizing based on ACCA calculations.

Rigging and handling

Safe procedures for lifting and moving the unit, including spreader bar use.

Typical wiring

Typical power wiring

Diagram showing field-supplied power connections to the unit.

Typical control wiring

Diagram illustrating thermostat and control board connections.

Typical cool;heat control wiring (Smart Equipment ZF036-076)

Specific wiring diagram for Smart Equipment controls.

Power and control wiring

Field wiring requirements conforming to NEC, CEC, and local codes.

Economizer interface

Smart Equipment economizer sequences

Sequences of operation for economizers with Smart Equipment controls.

Free cooling

Free cooling operation

How the first stage of cooling operates during free cooling.

Cooling Operation Sequences

Cooling sequence of operation

Sequence of operations for cooling with Simplicity Lite or Smart Equipment controls.

No outdoor air options

Economizer with single enthalpy sensor or dry bulb sensor

Economizer operation using single enthalpy or dry bulb sensors for cooling.

Economizer with dual enthalpy sensors

Economizer operation using dual enthalpy sensors for optimal efficiency.

Economizer with power exhaust

Cooling Operation Errors

High-pressure limit switch

How the high-pressure limit switch affects compressor and fan operation.

Low-pressure limit switch

How the low-pressure limit switch affects compressor and fan operation.

Freezestat (Simplicity Lite control)

How the freezestat operates and affects compressor operation.

Evaporator low limit (Smart Equipment control)

How the evaporator low limit sensor affects compressor operation.

Low ambient cooling (Simplicity Lite control)

Operation of the compressor in low ambient mode for Simplicity Lite.

Low ambient cooling (Smart Equipment control)

Operation of the compressor in low ambient mode for Smart Equipment.

Safety Controls

Electric heating sequence of operations

Sequences for single-stage and two-stage electric heating operation.

Compressor protection

Internal compressor protection and Anti-Short Cycle Delay (ASCD).

Flash codes or error messages

How the UCB indicates errors via flash codes or messages.

Gas Heating Operation

Gas heating sequence of operation

Step-by-step process for gas heating ignition and operation.

Two stage furnace only

Gas heat operation errors

Errors monitored during gas heating operation and fault code indications.

Temperature Limits

Gas valve

Centrifugal switch

Rollout switch

Flame sense circuit

Start-up Procedures

Prestart checklist

Checklist of items to verify after installation before initial start-up.

START-UP CHECKLIST

Checklist for common startup points and installation options.

Operating instructions

EQUIPMENT STARTUP

Instructions for using LCD or MAP Gateway for equipment startup.

Lighting the pilot and main burners

Procedure for safely lighting the pilot and main burners.

Gas Heat Checkout

Pilot checkout

Procedure for checking and adjusting the pilot flame.

Burner instructions

Manifold gas pressure adjustment

Checking gas input

Troubleshooting Guide

Cooling troubleshooting guide

Guide for troubleshooting cooling system issues, including blower and compressor.

Gas heat troubleshooting guide

Guide for troubleshooting gas heating system issues.

Flash Code Troubleshooting

Ignition control board

Troubleshooting the ignition control board and associated wiring.

Centrifugal switch

Troubleshooting the centrifugal switch for faults.

Symptomatic Troubleshooting

Symptomatic troubleshooting

Troubleshooting common symptoms like blower or draft motor issues.

Unit Flash Codes

Unit flash codes

Explanation of various flash codes used for troubleshooting.

Safety Warnings

DESIGN APPLICATION INFORMATION

Performance Measurements

OPERATING MEASUREMENTS - COOLING

REFRIGERANT SAFETIES

Checks for refrigerant safety systems and compressor rotation.

OPERATING MEASUREMENTS - GAS HEATING

Final Inspection and Controls

Verify Proper Operation of Heating;Cooling Staging Controls

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

FINAL - INSPECTION

Final checks of control set points, option parameters, and securing panels.

York ZF048 Specifications

General

Category	Air Conditioner
Refrigerant	R410A
Model Number	ZF048
Cooling Capacity	48000 BTU
Heating Capacity	48000 BTU