York ZF300 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 ZF300 Specifications

General

Brand	York
Model	ZF300
Category	Air Conditioner
Language	English

Summary

General

Safety Considerations

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

Inspection and Reference Information

Inspection

Guidelines for inspecting units upon receipt for potential transit damage.

Reference Information

Lists related technical documents and guides for further information.

Model Nomenclature

Product Category

Defines the product type, such as A/C, Single Pkg., R-410A.

Product Identifier

Specifies the EER rating for the A/C unit.

Nominal Cooling Capacity

Details the tonnage capacity of the unit.

Heat Type and Nominal Heat Capacity

Describes gas or electric heat options and their capacities.

Electric Heat Options

Lists available electric heat capacities in KW.

Airflow

Describes different airflow configurations and motor options.

Product Generation

Indicates the generation of the unit's design.

Standard Cabinet

Lists standard cabinet features and options.

Additional Options

Details various optional features and configurations available for the unit.

Voltage

Specifies the available voltage and frequency configurations.

Installation Options

Lists options related to installation configurations.

Options

Lists various accessory options available for the units.

Installation Safety and Limitations

FIRE OR EXPLOSION HAZARD

Warns about fire or explosion risks from improper handling or testing.

Limitations

Specifies installation requirements and codes that must be followed.

Unit Location, Clearances, and Handling

Location

Guidelines for selecting a suitable installation location for the units.

Clearances

Specifies required clearances for proper operation and servicing.

Rigging And Handling

Instructions for safely moving and lifting the unit.

Unit Weights and Dimensions

Unit Accessories and Utilities

Unit Dimensions and Duct Connections

For bottom duct applications

Instructions for connecting bottom ductwork.

For side duct applications

Instructions for connecting side ductwork.

Unit Clearances and Rain Hoods

Roof Curbs, Ductwork, and Air Dampers

Ductwork

Guidelines for designing and sizing ductwork systems.

Fixed Outdoor Air Intake Damper

Information on the fixed outdoor air intake damper installation.

Condensate Drain and Compressors

CAUTION

Warning about R-410A refrigerant and system requirements.

CAUTION

Warning about POE oil's hygroscopic nature and potential damage.

Filters and Wiring Precautions

CAUTION

Caution regarding compressor oil exposure to roofing materials.

CAUTION

Caution regarding drilling into internal components for disconnects.

CAUTION

Advice on using waterproof connectors for wiring.

Field Wiring and Thermostat Installation

Thermostat Wiring

Instructions for thermostat wiring and location selection.

Space Sensor

Guidelines for installing and locating space sensors.

Typical Thermostat Wiring Diagram

CAUTION

Caution regarding transformer tap adjustment for voltage.

Electrical Data

Physical Data

Optional Electric Heat and Minimum Supply Air

Optional Gas Heat and Gas Piping

Table 11: Gas Application Data

Data on gas heat input, output, and temperature rise.

Table 12: Gas Pipe Sizing - Capacity of Pipe

Table for sizing gas piping based on capacity and length.

Table 13: Gas Heat Minimum Supply Air

Table showing minimum supply air CFM for gas heat options.

Gas Connection and LP Gas Requirements

WARNING

Warning about propane's solvent properties and required pipe dope.

CAUTION

Caution regarding pressure testing of the gas supply piping.

WARNING

Warning about fire or explosion hazards when testing for gas leaks.

Options and Economizer Sequences

Economizer Sequences

Explains different economizer control sequences.

Free Cooling

Describes available free cooling options.

Dry Bulb Changeover

Explains free cooling operation based on dry bulb temperature.

Free Cooling and Power Exhaust Operation

Free Cooling Operation

Details how the unit operates in free cooling mode.

Power Exhaust

Details setpoints and operation for power exhaust systems.

Economizer Controller Board Details

Economizer Board Details (Continued)

Economizer Board Details (Continued)

Economizer Board Details and VAV Systems

Economizer Board Details (Continued)

Continues detailing economizer board terminals and functions.

Damper Set Points and VAV Systems

Details damper set points and VAV system integration.

Duct Static Pressure Transducer and VFD Systems

Factory-installed VFD

Details the factory-installed VFD, its wiring, and configuration.

BAS-Ready VFD

Information on BAS-ready VFD models and their connections.

VFD Installation and Hot Gas Bypass

Phasing, Blower Rotation, and Belt Tension

Phasing

Instructions for checking compressor and blower rotation phasing.

Belt Tension

Procedure for adjusting belt tension.

Altitude and Temperature Corrections

Drive Selection and Blower Performance

Drive Selection

Step-by-step guide for selecting the appropriate drive for the blower motor.

Example Supply Air Blower Performance

Sample performance data for supply air blowers.

Air Flow Performance - Side Duct

Air Flow Performance - Side Duct (Continued)

Air Flow Performance - Side Duct (Continued)

Air Flow Performance - Bottom Duct

Air Flow Performance - Bottom Duct (Continued)

Air Flow Performance - Bottom Duct (Continued)

RPM Selection and Blower Specifications

Air Balance

Procedures for balancing airflow in the conditioned space.

CAUTION

Caution regarding VFD drive settings and damper positions.

Airflow Adjustment and Static Resistance

Supply Air Drive Adjustment

Instructions for adjusting supply air blower RPM and pulley settings.

CAUTION

Caution regarding belt drive blower system adjustments.

Sequence of Operation and Cooling Errors

Compressor Operation

Explains compressor control based on thermostat inputs and safety delays.

Cooling Operation Errors

Describes common cooling system errors and their handling.

High-Pressure Limit Switch

Explains the function of the high-pressure limit switch.

Refrigerant Safety Controls and Electric Heat Operation

Low-Pressure Limit Switch

Details the low-pressure limit switch operation and lockout conditions.

Electric Heating Sequence Of Operations

Describes the operation of the electric heating section.

Electric Heat Limits and Anticipator Settings

Temperature Limit

Explains the function of temperature limit switches in electric heat units.

Electric Heat Anticipator Setpoints

Importance of correct anticipator setpoints for electric heat.

Gas Heating Sequence of Operations

CAUTION

Caution regarding VFD and gas heat operation.

Gas Heating Operation Errors and Controls

Gas Heating Operation Errors

Describes operational errors related to gas heating.

Safety Controls

Lists safety controls monitored for gas heat units.

Gas Heat Startup Procedures

Start-Up (Cooling)

Procedures for starting up the unit in cooling mode.

Start-Up (Gas Heat)

Procedures for starting up the unit in gas heat mode.

Gas Rate and Manifold Pressure Adjustment

Checking Gas Heat Input

Procedure for checking the gas heat input.

Manifold Gas Pressure Adjustment

Instructions for adjusting manifold gas pressure.

Temperature Rise and Burner Adjustments

Adjustment Of Temperature Rise

Procedure for adjusting temperature rise and calculating CFM.

Burner Instruction

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

Refrigerant Charging Charts

15 Ton Charging Chart

Charging chart for 15-ton units.

20 Ton Charging Chart

Charging chart for 20-ton units.

17.5 Ton Charging Chart

Charging chart for 17.5-ton units.

25 Ton Charging Chart

Charging chart for 25-ton units.

Simplicity SE Control Board Navigation

Understanding the Local LCD

Overview of the LCD display interface and basic navigation.

Control Board Navigation Steps

Unit Control Board Details

Unit Control Board Details (Continued)

Unit Control Board Details (Continued)

Unit Control Board Details (Continued)

Unit Control Board Details (Continued)

Unit Control Board Details (Continued)

Startup and Service Instructions

WARRANTY STATEMENT

Statement regarding the product's warranty coverage for startup failures.

EQUIPMENT STARTUP

Guide to using the local LCD or MAP Gateway for startup.

Safety Warnings and Design Application Information

DESIGN APPLICATION INFORMATION

Section for specifying engineer to provide design CFM and pressure data.

Reference Checklist

Operating Measurements - Air Flow and Electrical Data

Operating Measurements - Cooling and Gas Heating

OPERATING MEASUREMENTS - COOLING

Section for recording cooling operating measurements.

OPERATING MEASUREMENTS - GAS HEATING

Section for recording gas heating operating measurements.

Staging Controls and Final Inspection

FINAL - INSPECTION

Final inspection checklist for operational and safety checks.