York ZF076 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 ZF076 Specifications

General

Brand	York
Model	ZF076
Category	Air Conditioner
Language	English

Summary

General

Safety Considerations

Discusses safety alert symbols and signal words (DANGER, WARNING, CAUTION) for injury prevention.

Inspection

Details procedures for inspecting the unit for transit damage upon receipt.

Warnings and Cautions

Fire or Explosion Hazard

Warns about fire/explosion hazards from improper handling of flammable liquids and gas leaks.

Installation Compliance

Emphasizes strict compliance with installation instructions and codes for safe operation.

Reference

Lists additional information sources for design, installation, operation, and service.

Renewal Parts and Approvals

Renewal Parts

Information on obtaining authorized replacement parts from local distributors.

Approvals

Lists approved uses and installation types for the unit.

Installation Caution

Highlights the requirement for installation to comply with all applicable codes and regulations.

Installation Warning

Warns that improper installation can lead to personal injury or property damage.

Refrigerant System Caution

Notes the system uses R-410A refrigerant, which operates at higher pressures than R-22.

Product Nomenclature

Installation

Installation Safety Information

Read instructions before installation; ensure they are available to the consumer.

Limitations

Outlines installation requirements based on national and local codes and standards.

Location

Provides guidelines for selecting a suitable outdoor installation location for the units.

Rigging and Handling

Clearances

Details required clearances for proper unit operation and service access.

Condensate Drain and Compressors

Filters

Details filter types, installation, and maintenance requirements.

Service Access

Identifies removable panels providing access to serviceable components.

Wiring Diagrams

Typical Power Wiring

Illustrates typical field power wiring connections for single and three-phase supplies.

Typical Control Wiring

Shows typical control wiring connections between the thermostat and the unit control board.

Smart Equipment Control Wiring

Thermostat Installation

Provides guidelines for locating and installing the room thermostat.

Power and Control Wiring

Outlines requirements for field wiring, grounding, and voltage tolerances.

Optional Electric Heat

Gas Heat Installation

Optional Gas Heat

Describes gas-fired heaters, their heat exchangers, and ignition systems.

Gas Piping

Covers proper sizing of gas piping based on flow rate, gravity, and run length.

Gas Connection

Details routing of the gas supply line through unit knockouts.

Gas Piping Recommendations and LP Units

Gas Piping Recommendations

Provides recommendations for gas piping installation, including drip legs and unions.

L.P. Units, Tanks, and Piping

Discusses field conversion for LP/propane gas and associated equipment requirements.

Vent and Combustion Air Hoods

Optional Economizer/Motorized Damper Rain Hood

Refers to instructions for field assembly of an economizer rain hood.

Optional Power Exhaust/Barometric Relief Damper and Rain Hood

Refers to instructions for field assembly of power exhaust/barometric relief damper.

Economizer Interface

User Interface

Describes the components of the economizer user interface (LCD and keypad).

Keypad

Details the function of the navigation buttons for the economizer keypad.

Using the Keypad with Menus

Provides instructions on navigating menus using the keypad buttons.

Menu Structure

Lists the top-level menus available on the economizer controller.

RRS Economizer Controller Parameter Menu Functions

Explains that parameters are conditional based on sensor presence and function enablement.

Smart Equipment™™ Economizer Sequences

Discusses economizer sequences driven by Smart Equipment™ controls.

Economizer Minimum Position

Describes setting the economizer minimum position during occupied mode.

Free Cooling Operation

Dry Bulb Changeover

Details the conditions for free cooling using dry bulb temperature comparison.

Single Enthalpy Changeover

Details conditions for free cooling using single enthalpy comparison.

Dual Enthalpy Changeover

Details conditions for free cooling using dual enthalpy comparison.

Auto

Describes how the control determines free cooling type based on available sensors.

Free Cooling Operation

Explains how free cooling is implemented, including damper modulation and compressor engagement.

Thermostat

How thermostat inputs affect free cooling operation and compressor use.

Sensor

Discusses sensor inputs and their role in controlling supply air temperature during free cooling.

Power Exhaust System

Setpoints

Lists adjustable parameters for the power exhaust system.

Outputs

Describes the electrical outputs used to control external fans and actuators.

Operation

Explains how the power exhaust system operates in conjunction with the economizer.

Economizer Interface Details

Indoor Air Quality

Explains the function of indoor air quality sensors and their effect on actuator modulation.

Jade Economizer Interface Overview

Provides an overview of the Jade Economizer interface for Simplicity Lite controls.

User Interface

Describes the components of the Jade Economizer user interface (LCD and keypad).

Keypad

Details the function of the navigation buttons for the Jade Economizer.

Using the Keypad with Menus

Instructions for navigating menus using the keypad.

Keypad Usage and Economizer Setup

Using the Keypad with Settings and Parameters

How to use the keypad for settings, system setup, advanced settings, and alarms.

Menu Structure

Lists the order of menus displayed on the economizer module.

Economizer Setup and Configuration

Explains the initial setup and configuration process for the JADE™ Economizer module.

Time-Out and Screensaver

Describes the LCD screen saver behavior when the unit is inactive.

Enthalpy Settings

Unit Phasing and Airflow

Phasing

Discusses proper compressor rotation and how to correct misphased electrical connections.

Supply Air Blowers

Describes the types of supply air blowers used and their adjustment methods.

Checking Supply Airflow Rate

Explains how to determine the supply air blower speed based on performance data.

Blower System Adjustments

Blower System Adjustment Caution

Warns that belt drive blower systems require adjustment for specific static and CFM requirements.

Procedure for Adjusting Belt Tension

Step-by-step guide for adjusting belt tension on blower systems.

Blower Damage Warning

Warns about potential blower damage from improper system air quantity adjustment.

Cooling Operation Sequences

Cooling Sequence of Operation

Explains how the unit operates during cooling calls, including blower and compressor sequences.

Continuous Blower

Describes how to set the fan switch to "ON" for continuous blower operation.

Intermittent Blower

Explains operation when the fan switch is set to "AUTO".

No Outdoor Air Options

Describes the cooling operation sequence when no outdoor air options are present.

Economizer with Single Enthalpy Sensor or Dry Bulb Sensor

Details cooling operation with economizer using single enthalpy or dry bulb sensors.

Economizer with Dual Enthalpy Sensors

Describes economizer operation using dual enthalpy sensors for optimal efficiency.

Economizer with Power Exhaust

Explains how power exhaust integrates with economizer operation.

Cooling Operation Errors and Controls

Motorized Outdoor Air Dampers

Describes the operation of motorized outdoor air dampers.

Cooling Operation Errors

Outlines how the system handles cooling operation errors and safety shutdowns.

High-Pressure Limit Switch

Describes the function and behavior of the high-pressure limit switch during cooling.

Low-Pressure Limit Switch

Explains the monitoring and response to the low-pressure limit switch during cooling.

Freezestat (Simplicity Lite Control)

Details how the freezestat protects the system and initiates shutdown.

Evaporator Low Limit (Smart Equipment™ Control)

Describes the evaporator low limit sensor's function and shutdown procedures.

Low Ambient Cooling (Simplicity Lite Control)

Explains low ambient cooling mode operation for Simplicity Lite systems.

Low Ambient Cooling (Smart Equipment™ Control)

Explains low ambient cooling mode operation for Smart Equipment™ systems.

Safety Controls and Heating Operations

Safety Controls

Lists safety controls monitored by the unit control board for cooling systems.

Compressor Protection

Details inherent compressor protection features like anti-short cycle delay.

Flash Codes or Error Messages

Explains how the unit displays error codes or messages for troubleshooting.

Reset

How to reset pressure or freezestat lockouts by adjusting the thermostat.

Electric Heating Sequence of Operations

Describes the operational sequence for electric heating.

Single-Stage Heating

Explains the sequence for single-stage electric heating operation.

Two-Stage Heating

Explains the sequence for two-stage electric heating operation.

Safety Controls

Lists safety controls included in the electric heat control circuit.

Heating Limits and Gas Valve Operation

Flash Codes or Error Messages

Explains how the UCB initiates flash codes for system errors.

Reset

How to reset flash codes by adjusting the thermostat setting.

Heat Anticipator Setpoints

Discusses the importance of correct anticipator setpoints for heat cycles.

Gas Heating Sequence of Operation

Details the sequence of operation for gas heating.

Two Stage Furnace Only

Describes two-stage furnace operation with single or two-stage thermostats.

Gas Heat Operation Errors

Explains how the ICB monitors gas heat operation and handles errors.

Furnace Temperature Limits and Switches

Temperature Limits

Describes the location and function of temperature limits in the furnace.

Gas Valve

Explains how the UCB monitors the gas valve and handles faults.

Centrifugal Switch

Details the function and troubleshooting of the centrifugal switch.

Rollout Switch

Explains the purpose and troubleshooting of the rollout switch.

Flame Sense Circuit

Describes the flame sense circuit's role and failure indications.

Flash Codes or Error Messages

Explains how the UCB initiates flash codes for system errors.

Heat Anticipator Setpoints

Discusses the importance of correct anticipator setpoints for heat cycles.

Start-Up Procedures

Start-Up (Cooling)

Provides instructions for starting up the cooling system.

Prestart Checklist

Lists checks to perform after installation but before starting the unit.

Operating Instructions

Steps to follow for operating the unit in cooling mode.

Lighting the Pilot and Main Burners

Instructions for safely lighting the pilot and main burners on gas heat units.

Shutting Down the Unit

Procedures for safely shutting down the unit.

Post Start Checklist (Gas)

Checks to perform after the gas heating section has started operation.

Fire or Explosion Hazard Warning

Warns about fire/explosion hazards from improper testing of gas connections with open flames.

Gas System Checks and Adjustments

Pilot Checkout

Steps for checking and adjusting the pilot flame for proper operation.

Burner Instructions

Procedures for checking or changing burners, pilots, or orifices.

Manifold Gas Pressure Adjustment

How to adjust the high-fire gas flow by turning the pressure regulator screw.

Burner Air Shutter Adjustment

Instructions for adjusting burner shutters to prevent yellow flame.

Checking Gas Input

Procedures for checking the gas input rate to the furnace.

Temperature Rise Adjustment

Troubleshooting Guides

Cooling Troubleshooting Guide

Step-by-step guide for troubleshooting cooling system issues.

Troubleshooting Procedures

Gas Heat Troubleshooting Guide

Step-by-step guide for troubleshooting gas heating system issues.

Electrical Safety Caution

Emphasizes caution when working with live electrical components during troubleshooting.

Wiring Errors Caution

Advises labeling wires before disconnection to prevent wiring errors and dangerous operation.

Furnace Operation Troubleshooting

High Temperature Shutdown Warning

Warns that the furnace may shut down on high temperature during troubleshooting procedures.

Flash Code Troubleshooting

Guides on how to interpret and troubleshoot flash codes.

Ignition Control Board

Troubleshooting procedures for the ignition control board and its components.

Centrifugal Switch

Troubleshooting steps for issues related to the centrifugal switch.

Pilot and Rollout Switch Troubleshooting

Pilot Flame Lockout

Explains pilot flame lockout conditions and troubleshooting steps.

Primary or Aux Temperature Limit

Discusses temperature limits and their role in furnace operation and safety.

Rollout Switch

Troubleshooting steps for issues related to the rollout switch.

Symptomatic Troubleshooting

Unexpected Flame Presence

Troubleshooting steps for when a flame is present without a call for heat.

Gas Valve Stuck Off or On

Troubleshooting for gas valve operational issues.

Flame Sense Circuit Failure

Troubleshooting steps for flame sense circuit failures.

Unit Flash Codes and Fan Delays

Unit Flash Codes

Explains the various flash codes used by the control boards for troubleshooting.

Fan On and Off Delays

Describes how to field adjust fan ON and OFF delays.

Control Board Navigation

Navigation Components for the Smart Equipment™™ Control Board

Lists components needed to access Smart Equipment™ control points.

Smart Equipment™™ UCB Details

Limit, 24 VAC Power and Shutdown Connections

Details limit, power, and shutdown connections on the UCB.

UCB Terminal Connections

Terminal Thermostat Connection Strip

Details thermostat connection terminals on the UCB.

LEDs on Left Edge of UCB

Explains the status indicated by the LEDs on the UCB.

Space Temperature Sensor Connections

Describes space temperature sensor connections on the UCB.

Pin Temperature Sensor Connections

Details pin temperature sensor connections on the UCB.

UCB Pinned Connections

Pinned Connections on Right Edge of UCB

Lists pinned connections on the right edge of the UCB.

UCB Output and Safety Connections

Terminal at Lower Right Corner of UCB

Details terminals at the lower right corner of the UCB.

Pin Heat Section Connections

Describes heat section connection pins on the UCB.

Pin Cooling and Fan Output Connections

Details cooling and fan output connections on the UCB.

Pin Refrigerant Circuit Safety Switch and Indoor Blower Overload Connections

Explains refrigerant circuit safety switch and blower overload connections on the UCB.

UCB SA BUS and User Interface

Terminal SA BUS¹ Connections

Details SA BUS connections on the UCB.

Item Integrated User Interface

Lists components of the integrated user interface on the UCB.

Item USB Connector

Describes the USB connector on the UCB for data transfer.

Communication Board Connections

Terminal FC BUS¹ Connections

Details FC BUS connections on the communication board.

Item Selector in Red Housing

Describes the EOL selector switch on the communication board.

LEDs on the Communication Board

Explains the LEDs on the communication board.

Typical Wiring Diagrams

Simplicity® Lite Control Board

Shows the wiring diagram for the Simplicity Lite control board.

Start-Up Sheet Procedures

Start-Up Checklist

A checklist covering common startup procedures and points for package equipment.

Warranty Statement

Outlines the warranty policy for Johnson Controls/Ducted Systems equipment.

Equipment Startup

Instructions on using the local LCD or Mobile Access Portal for equipment startup.

Safety Warnings and Application Data

Safety Warnings

Critical safety warnings regarding lethal voltages and moving parts during startup.

Design Application Information

Section to record design application data like CFM and static pressures.

Reference Checklists

General Inspection

Checklist for inspecting the unit for shipping, installation, and general condition.

Air Moving Inspection

Inspection points related to the blower system, including alignment and tension.

Exhaust Inspection

Checklist for inspecting the exhaust fan and related components.

Economizer Inspection

Checklist for inspecting economizer operation and settings.

Operating Measurements - Air Flow

Electrical Data

Section to record electrical measurements like voltage and amperage for various components.

Operating Measurements - Cooling

Refrigerant Safeties

Checks related to refrigerant circuit safety controls and compressor rotation.

Operating Measurements - Gas Heating

Lists measurements to record for gas heating operation, including gas pressure and temperature rise.

Operational Measurements - Staging Controls

Verify Proper Operation of Heating/Cooling Staging Controls

Steps to verify correct staging of heating and cooling stages.

Verify Proper Operation of the Variable Frequency Drive

Steps to verify the variable frequency drive's modulation with duct pressure.

Final - Inspection

Final inspection steps, including set point verification and panel closure.