York ZF180 User Manual

R-410A
ZF SERIES
15 & 20 Ton/53 & 70 KW
50 Hertz
5168276-XIM-B-0216
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Economizer Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ZF180-240 Side Duct Application . . . . . . . . . . . . . . . . . . . . . . 31
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 37
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 39
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 39
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 40
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 40
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic
Unit Control Board Navigation Examples: . . . . . . . . . . . . . . . . 45
LIST OF TABLES
1 ZF180-240 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZF180-240 Unit Weights Imperial . . . . . . . . . . . . . . . . . . . . . . 8
3 ZF180-240 Unit Weights Metric . . . . . . . . . . . . . . . . . . . . . . . . 8
4 ZF180-240 Unit Accessory Weights Metric . . . . . . . . . . . . . . . 8
5 ZF180-240 Unit Accessory Weights Imperial . . . . . . . . . . . . . 8
6 Utilities Entry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 ZF180-240 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 ZF180-240 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 20
13 Gas Heat Minimum Supply Air Imperial . . . . . . . . . . . . . . . . . 20
14 Gas Heat Minimum Supply Air Metric . . . . . . . . . . . . . . . . . . 20
15 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . . . 24
16 Altitude/Temperature Correction Factors Imperial . . . . . . . . 28
17 Altitude/Temperature Correction Factors Metric . . . . . . . . . . 28
18 Air Flow Performance - Side Duct Application . . . . . . . . . . . 31
19 Air Flow Performance - Bottom Duct Application . . . . . . . . . 33
20 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
21 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 35
22 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 35
23 Additional Static Resistance Imperial . . . . . . . . . . . . . . . . . . 36
24 Additional Static Resistance Metric . . . . . . . . . . . . . . . . . . . . 36
25 Limit Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
26 Electric Heat Anticipator Setpoint . . . . . . . . . . . . . . . . . . . . . 40
27 Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . . . . . . . . 42
28 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 42
29 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 43
30 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LIST OF FIGURES
1 ZF180-240 Component Location . . . . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Unit Dimensions - ZF Cooling Only . . . . . . . . . . . . . . . . . . . . 9
6 Unit Dimensions - ZF Gas Heat . . . . . . . . . . . . . . . . . . . . . . . 9
7 ZF180-240 Unit Dimensions Rear View . . . . . . . . . . . . . . . . 10
8 ZF180-240 Unit Dimensions Rain Hood . . . . . . . . . . . . . . . . 11
9 Roof Curb Dimensions (All Models) . . . . . . . . . . . . . . . . . . . 12
10 Roof Curb Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
11 Unit Curb And Applications . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Fixed Outdoor Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14 Field Wiring Disconnect - Cooling Unit With/Without Electric
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . . . . . 16
16 External Supply Connection External Shut-Off . . . . . . . . . . . 20
17 Bottom Supply Connection External Shut-Off . . . . . . . . . . . 20
18 Vent and Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 22
19 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 24
20 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
21 Altitude/Temperature Correction Factors Imperial . . . . . . . . 29
22 Altitude/Temperature Correction Factors Metric . . . . . . . . . 29
23 Pressure Drop Across A Dry Indoor Coil Vs. Supply Air CFM
For All Unit Tonnages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
24 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
25 Gas Heat Limit And Auxiliary Location Down Discharge
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
26 Gas Heat Limit and Auxiliary Location Side Discharge
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
27 Gas Valve and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
28 Proper Pilot Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . 44
29 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
30 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
31 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
32 Start-Up & Service Data Instruction . . . . . . . . . . . . . . . . . . . 53

York ZF180 Specifications

General

Brand	York
Model	ZF180
Category	Air Conditioner
Language	English

Summary

General

Safety Considerations

General safety advice and understanding of hazard signal words.

Installation and Refrigerant Safety

Cautions on improper installation, R-410A refrigerant, and fire/explosion risks.

Nomenclature

Model Number Breakdown

Explanation of the model number encoding for ZF units.

Installation

Installation Safety and Limitations

Safety guidelines, code compliance, and unit limitations for installation.

Location and Handling

Unit Placement Guidelines

Selecting suitable locations and ensuring adequate air supply.

Rigging and Clearances

Safe lifting procedures and required clearances for unit installation.

Unit Dimensions

ZF Unit Dimensional Views

Illustrates dimensions for cooling-only and gas heat ZF units.

Utilities Entry and Duct Connections

Utility Entry Data

Details on unit entry points for wiring and piping.

Duct Connection Procedures

Instructions for bottom and side ductwork connections.

Unit Clearances and Rain Hoods

Rain Hood Installation

Details on unit dimensions with rain hoods installed.

Clearance Requirements

Specifies minimum distances for unit clearances.

Ductwork and Curb Installation

Ductwork Design and Installation

Designing ductwork per ACCA/ASHRAE standards for proper air distribution.

Roof Curb Dimensions and Benefits

Information on roof curb dimensions, applications, and benefits.

Unit Components and Drains

Fixed Outdoor Air Intake Damper

Installation and adjustment of the outdoor air intake damper.

Condensate Drain Requirements

Plumbing for condensate drain, including trapping.

Compressor Specifications

Details on scroll compressors, R-410A refrigerant, and POE oil.

Filters and Wiring

Filter Installation and Maintenance

Proper installation and upkeep of unit filters.

Power and Control Wiring

Compliance with electrical codes and requirements for wiring.

Wiring and Sensor Installation

Field Wiring Disconnect

Requirements and installation of a disconnect switch.

Thermostat and Space Sensor Installation

Guidelines for installing thermostats and space sensors.

Wiring Diagrams

Typical 24 Volt Thermostat Wiring

Diagram illustrating typical thermostat wiring connections.

Electrical Data

ZF180-240 Electrical Specifications

Table detailing electrical data for unit operation.

Physical Data

Cooling and Heating Performance

AHRI cooling and heating performance metrics.

Unit Dimensions and Components

Physical dimensions, compressor, and coil data.

Physical Data (Continued)

Fan and Filter Specifications

Details on condenser and evaporator fan data, and filter sizes.

Gas Heat and Piping

Optional Gas Heat and Application Data

Information on gas heat options and application data.

Gas Piping Sizing and Connections

Guidelines for sizing gas piping and making connections.

Gas Piping Safety

Natural Gas and LP Gas Piping Warnings

Safety warnings for gas piping, including LP gas considerations.

Air Handling and Economizer

Vent and Combustion Air Hoods

Installation instructions for vent and combustion air hoods.

Economizer Operation Modes

Overview of economizer sequences and free cooling options.

Economizer and Exhaust Operation

Free Cooling Operation Details

How thermostats and sensors control free cooling.

Power Exhaust Configuration

Setpoints and operation of the power exhaust system.

Simplicity SE Economizer Controller

Controller Overview and Navigation

Introduction to the SE-ECO1001 controller and basic LCD navigation.

Analog Inputs and LEDs

Details on analog input terminals and status LEDs on the board.

Economizer Board Connections

SA BUS and Analog Output Pins

Pin connections for SA BUS and analog outputs for control.

Binary Output Pins

Pin connections for binary outputs controlling fans and actuators.

Economizer Board Connections (Continued)

24V IN and Analog Input Pins

Power connections and input pins for various sensors.

Economizer Board Adjustments

Binary Input Pins

Input connections for building pressure and purge contacts.

Phasing and Belt Tension

Procedures for checking rotation and adjusting belt tension.

Altitude and Temperature Corrections

Correction Factor Tables

Tables providing imperial and metric correction factors.

Altitude Correction Factor Graphs

Correction Factor Graphs

Graphical representations of correction factors based on air temperature and altitude.

Altitude Correction Example

Example demonstrating the use of correction factors for performance data.

Blower Drive Selection

Drive Selection Procedure

Steps to select blower speed and drive based on performance data.

Blower Performance and RPM Tables

Tables for blower performance and RPM selection.

Air Flow Performance - Side Duct

15 Ton Side Duct Performance Data

Performance data for the 15-ton unit in side duct configuration.

Air Flow Performance - Side Duct (Continued)

20 Ton Side Duct Performance Data

Performance data for the 20-ton unit in side duct configuration.

Air Flow Performance - Bottom Duct

15 Ton Bottom Duct Performance Data

Performance data for the 15-ton unit in bottom duct configuration.

Air Flow Performance - Bottom Duct (Continued)

20 Ton Bottom Duct Performance Data

Performance data for the 20-ton unit in bottom duct configuration.

Blower Adjustments and Air Balance

RPM Selection and Blower Specifications

Tables for RPM selection and indoor blower specifications.

Air Balance Procedures

Steps for balancing air distribution and checking supply air CFM.

Supply Air Drive Adjustment

RPM and Static Resistance Adjustments

Adjusting blower RPM and static resistance for optimal performance.

Cooling Sequence of Operation

Cooling Stage Operations

Sequence for first/second stage cooling, continuous/intermittent blower.

Economizer Cooling Sequences

Operation with single and dual enthalpy sensors for free cooling.

Economizer, Exhaust, and Cooling Errors

Economizer with Power Exhaust

Operation of economizer when equipped with power exhaust.

Motorized Outdoor Air Dampers

Operation of motorized dampers for outdoor air control.

Cooling Operation Error Handling

Response to high/low pressure, evaporator low limit, and low ambient conditions.

Safety Controls and Electric Heat

Safety Control Monitoring

Monitoring of evaporator low limit, pressure switches, and compressor protection.

Electric Heating Sequences

Operation sequences for single and two-stage electric heating.

Gas Heating Sequences

Gas Heating Operation

Sequence for first/second stage gas heating, including errors.

Gas Heat Safety Controls

Gas Valve and Limit Switches

Monitoring of gas valve, limit switches, and centrifugal switch.

Redundant Gas Valve and Rollout Switch

Safety features of the gas valve and rollout switch.

Gas Heat Settings and Start-Up

Gas Heat Limit Control Settings

Table for gas heat limit control settings.

Gas Heat Anticipator Setpoints

Table for electric heat anticipator setpoints.

Gas Heat Start-Up Procedures

Start-Up Checklists and Instructions

Pre-start checks, operating instructions, and post-start checks.

Checking Gas Heat Input

Procedure for measuring gas consumption and verifying input.

Gas Pressure and Burner Adjustments

Manifold Gas Pressure Adjustment

Adjusting the gas pressure regulator screw for correct manifold pressure.

Pilot Checkout and Burner Service

Adjusting pilot flame and instructions for burner service.

Simplicity SE Control Navigation

LCD Display and Basic Navigation

Overview of the LCD display and basic menu navigation.

Simplicity SE Control Navigation (Continued)

Commissioning Menu and Set Point Changes

Navigating commissioning menus and changing set points.

Unit Control Board Details

UCB Terminal Connections

Description of UCB terminals for power, shutdown, and signals.

UCB Status LEDs

Explanation of Power, Fault, and SA Bus LED indicators.

UCB Terminal Details

Thermostat and Sensor Connections

Details on thermostat and space/supply air sensor connections.

UCB Terminal Details (Continued)

Temperature and Humidity Sensor Connections

Connections for return air, outside air, and coil sensors.

Input/Output Pin Connections

Details on connections for switches and VFD outputs.

UCB Output and Safety Connections

Output Terminals and Safety Switches

Connections for heat, fan, compressor outputs, and safety switches.

UCB Terminal Details (Continued)

Safety Switch and SA BUS Connections

Continued safety switch connections and SA BUS terminals.

Integrated User Interface

Description of the on-board display, buttons, and joystick.

UCB Communication Details

USB and SA Bus Connectors

Connectors for software updates and SA Bus communication.

Communication Board LEDs and Terminals

Status LEDs and terminals for communication sub-board.

Start-Up and Service Data

Startup Checklist and Procedures

Checklist and instructions for equipment startup.

Design Application Information

Entering Design Application Data

Fields for recording system design parameters.

Reference and Inspection Checklists

General and Air Moving Inspections

Checklists for general unit inspection and air moving components.

Exhaust and Economizer Inspections

Checklists for exhaust fan and economizer system inspections.

Operating Measurements - Air Flow

Air Flow Measurement and Motor Data

Recording air flow measurements and motor/pulley data.

Electrical Data Recording

Fields for logging electrical data of unit components.

Operating Measurements - Cooling and Gas Heating

Cooling Refrigerant Measurements

Recording cooling system pressures, temperatures, and safeties.

Gas Heating Measurements

Recording gas heating checks, manifold pressure, and temperature rise.

Operational Measurements and Final Inspection

Staging Controls and VFD Verification

Verifying heating/cooling staging and VFD operation.

Final Inspection Checks

Final checks of set points, options, and access panels.