York ZF210 User Manual

R-410A
ZF SERIES W/SIMPLICITY SE
15 - 25 Ton
60 Hertz
1088917-YIM-B-1014
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 Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 30
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 31
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Optional BAS-Ready Economizer Power Exhaust Damper
Set Point Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . 35
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . 37
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 49
Electric Heating Sequence Of Operations . . . . . . . . . . . . 50
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 51
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 52
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 53
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Simplicity™ SE (Smart Equipment) Firmware Version 3.
Basic Unit Control Board Navigation Examples: . . . . . . . . 58
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
LIST OF TABLES
1 ZF180-300 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZF180-300 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9
4 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Supply Fan VFD Weights, In Lbs. . . . . . . . . . . . . . . . . . . . 9
6 ZF180-300 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 ZF180-300 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 26
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 27
11 Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 28
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 28
14 Simplicity SE Economizer Board Details . . . . . . . . . . . . 32
15 Altitude/Temperature Correction Factors . . . . . . . . . . . . 39
16 Air Flow Performance - Side Duct Application . . . . . . . . 41
17 Air Flow Performance - Bottom Duct Application . . . . . . 44
18 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
19 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . 47
20 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 47
21 Limit Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22 Electric Heat Anticipator Setpoint . . . . . . . . . . . . . . . . . . 52
23 Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . . . . . 53
24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54
25 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 55
26 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . 60
LIST OF FIGURES
1 ZF180-300 Component Location . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZF180-300 Unit Dimensions Front View . . . . . . . . . . . . . 9
6 ZF180-300 Unit Dimensions Rear View . . . . . . . . . . . . . 10
7 ZF180-300 Unit Dimensions Rain Hood . . . . . . . . . . . . 11
8 ZF180 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 ZF210-300 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10 Fixed Outdoor Air Damper . . . . . . . . . . . . . . . . . . . . . . . 13
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12 Field Wiring Disconnect - Cooling Unit With/Without Electric
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . 16
14 External Supply Connection External Shut-Off . . . . . . . 28
15 Bottom Supply Connection External Shut-Off . . . . . . . . 28
16 Vent and Combustion Air Hood . . . . . . . . . . . . . . . . . . . 30
17 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 32
18 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
19 Altitude/Temperature Correction Factors . . . . . . . . . . . . 39
20 Pressure Drop Across A Dry Indoor Coil Vs. Supply Air CFM
For All Unit Tonnages . . . . . . . . . . . . . . . . . . . . . . . . . . 48
21 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
22 Gas Valve and Controls . . . . . . . . . . . . . . . . . . . . . . . . . 53
23 Proper Pilot Flame Adjustment . . . . . . . . . . . . . . . . . . . 56
24 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
25 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
26 ZF180 (15 Ton) Charging Chart . . . . . . . . . . . . . . . . . . . 57
27 ZF210 (17.5 Ton) Charging Chart . . . . . . . . . . . . . . . . . 57
28 ZF240 (20 Ton) Charging Chart . . . . . . . . . . . . . . . . . . . 57
29 ZF300 (25 Ton) Charging Chart . . . . . . . . . . . . . . . . . . . 57
30 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

York ZF210 Specifications

General

Model Number	ZF210
Category	Air Conditioner
Refrigerant	R410A
Cooling Capacity	21000 BTU
Heating Capacity	22000 BTU
Power Supply	220-240V, 50Hz
Sound Pressure Level (Indoor)	45 dB(A)

Summary

General

Safety Considerations

Explains the meaning of DANGER, WARNING, and CAUTION symbols.

General

Approvals

Lists CSA certifications for unit design and application.

Installation

Installation Safety Information

Provides critical safety instructions for unit installation procedures.

Limitations

Details installation requirements and codes for the unit.

Location

Clearances

Specifies required clearances for unit operation and servicing.

Rigging And Handling

Ductwork

Fixed Outdoor Air Intake Damper

Describes installation and adjustment of the fixed outdoor air intake damper.

Condensate Drain

Compressors

Filters

Power And Control Wiring

Power Wiring Detail

Details how power wiring is brought into the unit and sized.

Thermostat Wiring

Space Sensor

Optional Electric Heat

Optional Gas Heat

Gas Piping

Provides guidelines for proper gas piping sizing and installation.

Gas Connection

Gas piping recommendations

Lists key recommendations for safe and proper gas piping installation.

Lp Units, Tanks And Piping

Discusses conversion to LP gas and requirements for its safe use.

Options/Accessories

Economizer Sequences

Explains various functions driving the economizer operation.

Free Cooling

Details the four types of free cooling options available.

Power Exhaust

Describes the power exhaust option and its settings.

Dual Enthalpy Changeover

Auto

Free Cooling Operation

Thermostat

How thermostats control dampers and compressors during free cooling.

Power Exhaust

Setpoints

Lists adjustable setpoints related to power exhaust and economizer functions.

Simplicity SE Economizer Controller

Simplicity SE Economizer Board Details

Details the function and comments for each cover label on the economizer board.

Simplicity SE Economizer Board Details (Continued)

SA BUS Pin connections

Explains SA BUS pin connections and their functions on the economizer board.

ANALOG OUTPUTS Pin

Details analog output pins for VFD control and economizer actuators.

BINARY OUTPUTS Pin

Details binary output pins for exhaust fan and economizer actuators.

Simplicity SE Economizer Board Details (Continued)

24V~ IN Pin connections

Explains 24VAC input connections for sensors and power on the economizer board.

ANALOG INPUTS Terminal

Details analog input terminals for humidity, supply air, and quality sensors.

Simplicity SE Economizer Board Details (Continued)

BINARY INPUTS

Details binary input connections for purge and VFD fault contacts.

Power Exhaust Damper Set Point

How to set the power exhaust damper position.

Indoor Air Quality AQ

Explains how the AQ sensor affects damper modulation and control.

Optional Variable Air Volume (VAV)

Describes the VAV option using a VFD for static pressure control.

Duct Static Pressure Transducer

Factory-installed VFD

Manual Bypass

Explains the operation of the manual bypass switch for the VFD.

BAS-Ready VFD

Describes BAS-ready VFD models and their control wiring connections.

'VFD-Ready' For Customer-installation

Optional Hot Gas Bypass (HGBP)

Phasing

Blower Rotation

Belt Tension

CFM Static Pressure and Power-Altitude and Temperature Corrections

Altitude/Temperature Correction Factors

Example 1

Demonstrates calculating corrected CFM, static pressure, and BHP at altitude.

Example 2

Demonstrates determining blower speed and BHP for a given CFM and static pressure at altitude.

Drive Selection

Example

A step-by-step example of selecting a drive based on CFM and static pressure.

Air Flow Performance - Side Duct Application

Air Flow Performance - Bottom Duct Application

Air Balance

Supply Air Drive Adjustment

Explains how to adjust blower speed and belt tension for required CFM.

Additional Static Resistance

Sequence of Operation

Compressor Operation

Details how compressors are controlled by thermostat inputs and safety features.

Cooling Operation Errors

Describes how cooling system errors are monitored and handled.

High-Pressure Limit Switch

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

Low-Pressure Limit Switch

Evaporator Low Limit

Low Ambient Cooling

Safety Controls

Compressor Protection

Temperature Limit

Electric Heat Operation Errors

Safety Controls

Temperature Limit Switch (TLS)

Electric Heat Anticipator Setpoints

Gas Heating Sequence Of Operations

Gas Valve Piping

Illustrates the gas valve piping configuration for ignition and main burners.

Gas Heating Operation Errors

Temperature Limit

How zero volts from the high temp limit affects blower and draft motor.

Gas Valve

How the UCB monitors the gas valve and blower operation.

Safety Controls

Lists safety controls monitored by the ICB for gas heat units.

Limit Switch (LS)

Explains the function of the automatic reset limit switch in the gas heat compartment.

Centrifugal Switch (CS)

How the centrifugal switch on the draft motor prevents ignition.

Redundant Gas Valve

Describes the function of redundant gas valves for safety.

Flame Sensor Rod / 100% Ignition Control Lock-Out.

Explains flame sensor function and ignition control lockout.

Rollout Switch

The function of the rollout switch in preventing burner rollout.

Auxiliary Limit Switch (AUX)

The purpose and function of the manual reset auxiliary limit switch.

Gas Heat Anticipator Setpoints

Start-Up (Cooling)

Prestart Check List

Pre-startup checks for electrical supply, thermostat, and blower rotation.

Operating Instructions

Steps for turning on the unit and setting the thermostat for cooling.

Post Start Check List

Checks to perform after the cooling system is operating.

Start-Up (Gas Heat)

Pre-Start Check List

Checks before starting the gas heat unit, including gas type and hood installation.

Operating Instructions

How to light the main burners and set the thermostat for gas heat.

Post Start Checklist

Checks to perform after the heating section is operating, including gas leaks.

Checking Gas Heat Input

Manifold Gas Pressure Adjustment

Adjustment Of Temperature Rise

Burner Instruction

Burner Air Shutter Adjustment

Pilot Checkout

Charging The Unit

15 Ton Charging Chart

Chart for charging the 15-ton unit based on suction and discharge pressures.

17.5 Ton Charging Chart

Chart for charging the 17.5-ton unit based on suction and discharge pressures.

20 Ton Charging Chart

Chart for charging the 20-ton unit based on suction and discharge pressures.

25 Ton Charging Chart

Chart for charging the 25-ton unit based on suction and discharge pressures.

Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic Unit Control Board Navigation Examples:

Understanding the Local LCD

How to navigate the LCD display and the basic functions.

LCD Display Navigation

Step-by-step guide to navigating the LCD display menus.

Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic Unit Control Board Navigation Examples:

Commissioning Menu Navigation

Demonstrates navigating the commissioning menu to change settings.

Unit Control Board

Simplicity SE UCB Details

Details the connections and functions of the Unit Control Board (UCB) terminals.

Simplicity SE UCB Details (Continued)

Terminal Thermostat connection strip

Explains thermostat connection strip terminals and their functions.

LEDs on left edge of UCB

Describes the status indicators (LEDs) on the left edge of the UCB.

Terminal Space temperature sensor connections

Details space temperature sensor connections and their functions.

Pin Temperature sensor connections

Details pin temperature sensor connections for supply air.

Simplicity SE UCB Details (Continued)

Return Air Temperature sensor input

Explains inputs for Return Air Temperature, Outside Air Temperature, and coil sensors.

Pinned connections on right edge of UCB

Details pinned connections on the right edge of the UCB for humidity and pressure sensors.

Simplicity SE UCB Details (Continued)

Terminal at lower right corner of UCB

Describes terminals at the lower right corner for output relays and heat section connections.

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

Details connections for refrigerant safety switches and blower overload.

Simplicity SE UCB Details (Continued)

Terminal SA BUS connections

Explains SA BUS connections for devices and gateways.

Item Integrated user interface

Describes the integrated user interface components like Display, Enter, Cancel, Joy.

Simplicity SE UCB Details (Continued)

Item USB connector

Describes the USB connector for backup and software updates.

Optional communication sub-board

Details connections for the optional communication sub-board (FC BUS, EOL).

Start-Up Sheet

START-UP CHECKLIST

A checklist for performing unit startup and service data recording.

WARRANTY STATEMENT

Details the warranty coverage for new equipment startup failures.

EQUIPMENT STARTUP

Instructions on using the LCD or MAP Gateway for equipment startup.

SAFETY WARNINGS

DESIGN APPLICATION INFORMATION

REFERENCE

General Inspection

Checklist for general unit inspections before operation.

Air Moving Inspection

Checklist for inspecting air moving components like alignment and belt tension.

Exhaust Inspection

Checks related to exhaust fan operation and mounting.

Economizer Inspection

Checks for economizer settings, CO2 sensor, and operation.

Operating Measurements - Air Flow

ELECTRICAL DATA

Table for recording nameplate and measured electrical data for unit components.

OPERATING MEASUREMENTS - COOLING

REFRIGERANT SAFETIES

Prove Compressor Rotation

Check for proper compressor rotation using gauge pressure.

Prove High Pressure Safety

Verifying the function of the high-pressure safety system.

Prove Low Pressure Safety

Verifying the function of the low-pressure safety system.

OPERATING MEASUREMENTS - GAS HEATING

Check for gas leaks

Action item to check for gas leaks in the unit piping.

Prove Ventor Motor Operation

Verifying the operation of the ventor motor.

Prove Primary Safety Operation

Verifying the operation of primary safety controls.

Prove Auxiliary Safety Operation

Verifying the operation of auxiliary safety controls.

Prove Rollout Switch Operation

Verifying the operation of the rollout switch.

Prove Smoke Detector Operation

Verifying the operation of the smoke detector.

Manifold Pressure

Action item to check manifold pressure in stages.

Supply gas pressure at full fire

Action item to check supply gas pressure at full fire.

Check temperature rise

Action item to check temperature rise during gas heating operation.

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

Verify Proper Operation of Heating/Cooling Staging Controls

Verifying proper operation of heating and cooling staging controls.

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

Verifying proper operation of the variable frequency drive.

FINAL - INSPECTION

Verify that all operational control set points have been set to desired value

Verifying all control set points are set correctly for occupancy requirements.

Verify that all option parameters are correct

Ensuring all installed options are enabled and others disabled in software.

Verify that all access panels have been closed and secured

Ensuring all access panels are closed and secured after inspection.