York ZJ Series - User Manual

R-410A
ZJ SERIES W/SMART EQUIPMENT™
3 - 5 Ton
60 Hertz
5565591-YIM-B-1019
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 31
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 31
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 46
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 46
Electric Heating Sequence Of Operations . . . . . . . . . . . . 47
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 48
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 49
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 49
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control Board Navigation Components . . . . . . . . . . . . . . . . . 54
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LIST OF TABLES
1 ZJ037-061 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZJ037-061 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8
4 ZJ037-061 Unit Physical Dimensions . . . . . . . . . . . . . . . 11
5 ZJ037-061 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 27
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 28
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 29
14 Smart Equipment™ Economizer Board Details . . . . . . . 33
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16 Altitude/Temperature Correction Factors . . . . . . . . . . . . 37
17 Airflow Performance - Side Duct Application . . . . . . . . . 40
18 Airflow Performance - Bottom Duct Application . . . . . . . 4 1
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . 42
21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 42
22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 44
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 45
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 48
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 48
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 50
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 52
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . 55
30 Cable for FC Buses and SA Buses in Order of Preference . 60
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . 60
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Component Location (ZJ037 Shown) . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZJ037 - 049 Physical Dimensions . . . . . . . . . . . . . . . . . . 9
9 ZJ061 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 10
10 ZJ037-061 Unit Bottom Duct Openings . . . . . . . . . . . . . 1 2
11 ZJ037-061 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13
12 ZJ037-061 Unit Side Duct Openings . . . . . . . . . . . . . . . 1 3
13 ZJ037-061 Unit Left/End Duct Opening . . . . . . . . . . . . . 1 4
14 ZJ037-061 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZJ037-061 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15
16 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 15
17 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 16
18 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . 16
19 Save Side Panels For Economizer Hood Tops . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19
23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 28
25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 3 3
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . 38
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
29 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
30 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . 53
31 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . 54
32 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Summary

General Information and Safety

Installation Safety Considerations

Key safety warnings and cautions regarding unit installation and operation.

Fire and Explosion Hazard Warning

Warning about fire or explosion risk due to improper handling of flammable vapors.

Unit Inspection and Handling

Improper Installation Warning

Warning about personal injury or property damage from improper installation.

Model Number Nomenclature

Nomenclature Breakdown

Detailed explanation of each component of the unit model number.

Installation Procedures

Installation Safety Information

Essential safety information to read before starting installation.

Installation Fire and Explosion Hazard

Warning regarding fire or explosion risk during installation procedures.

Installation Limitations and Codes

Applicable Codes and Standards

Lists relevant electrical, fuel gas, and building codes for installation.

Unit Location Guidelines

Contaminated Air Warning

Warning about damage or injury from contaminated combustion air.

Airflow Obstruction Warning

Warning against obstructing condenser air discharge or combustion air inlets.

Required Clearances

Specifies clearances needed for operation and service.

Ductwork Design and Installation

Compressor Information

R-410 A Refrigerant Caution

Caution regarding R-410A refrigerant and system compatibility.

Filter Installation and Maintenance

Power and Control Wiring

Transformer Voltage Tap Adjustment

Caution about adjusting transformer taps for different voltage supplies.

Water-Proof Connector Caution

Caution to use water-proof connectors for wiring to prevent moisture ingress.

Power Wiring Details

Thermostat Wiring and Control

Typical Control Wiring Diagram

Diagram illustrating typical thermostat and control board wiring connections.

Optional Gas Heat System

Gas Piping Requirements

Natural Gas Piping Warning

Warning about using proper pipe dope with natural gas due to solvent properties.

Gas Leak Testing Warning

Warning against using open flames for gas leak detection.

Gas System Pressure Testing Caution

LP Gas Piping Compound Warning

Warning to use specific compounds for LP gas piping to prevent dissolution.

Gas Connection Procedures

Gas Piping Recommendations

Natural Gas Piping Material Warning

Warning on suitable pipe dope for natural gas to prevent damage.

Gas Fire or Explosion Hazard

Hazard warning for fire or explosion from improper gas handling.

Gas Pressure Testing Caution

Economizer System

Free Cooling Modes

Unit Phasing and Rotation Checks

Rotation Correction Caution

Blower Belt Tension Adjustment

Belt Tension Adjustment Caution

Blower Drive Selection Procedure

Drive Selection Example

Air Balancing Procedure

Air Balancing Caution

Checking Air Quantity (CFM)

Air Quantity Adjustment Warning

Air Quantity Measurement Method Two

Supply Air Drive Adjustment

Drive Adjustment Example

Drive Adjustment Caution

Unit Operation Modes

Cooling Sequence of Operation

Detailed description of the cooling system's operational sequence.

Cooling Operation Error Handling

High-Pressure Limit Switch Operation

Low-Pressure Limit Switch Operation

Evaporator Low Limit Sensor Operation

Cooling System Safety Controls

Compressor Protection Features

Electric Heating Sequence of Operations

Electric Heat Operation Errors

Electric Heat Safety Controls

Electric Heat Limit Switch Operation

Gas Heating Sequence of Operations

Gas Heating First Stage Operation

Detailed steps for the first stage of gas heating ignition and operation.

Gas Heating Second Stage Operation

Detailed steps for the second stage of gas heating ignition and operation.

Gas Heating Retry Operation

Gas Heating Recycle Operation

Gas Heating Operation Errors

Conditions that cause a gas heating lock-out and how to reset.

Internal Microprocessor Failure

Start-Up Procedures (Cooling)

Cooling Start-Up Pre-Checklist

Essential checks before starting the cooling system.

Cooling Start-Up Operating Instructions

Initial operating steps after completing cooling start-up.

Lighting the Main Burners (Gas Heat)

Pilot Lighting Caution

Gas Heat Post Start Checklist

Checks to perform after the heating section is operating.

Checking Gas Heat Input

Procedure for measuring and verifying gas heat input rates.

Gas Heat Flow Rate Determination (Second Stage)

Steps to measure gas flow for second stage heating input.

Gas Heat Pressure Adjustment

Procedure for adjusting gas pressure regulators for optimal input.

Gas Heat Flow Rate Determination (First Stage)

Manifold Gas Pressure Adjustment

Gas Heat Temperature Rise Adjustment

Burner and Orifice Inspection;Servicing

Control Board Navigation

Unit Charging Procedure

UCB Limit, Power, and Shutdown Connections

UCB Thermostat Connection Terminals

UCB Input;Output Pin Connections

UCB Cooling and Fan Output Connections

UCB Refrigerant Safety and Blower Overload Connections

UCB SA Bus Connections

UCB Integrated User Interface

Start-Up and Service Data Instructions

Start-Up Checklist

A checklist of items to verify before and during equipment start-up.

Equipment Start-Up Method

Instructions on using LCD or MAP Gateway for start-up.

Safety Warnings for Startup Procedures

Lethal Voltage Warning

Warning about lethal voltages present during some start-up checks.

Moving Parts Warning

Warning about exposed moving parts during start-up checks.

Design Application Information

Operating Measurements: Air Flow

Fan Rotation Verification

Evaporator Coil Pressure Drop Measurement

Supply Air CFM Calculation

Electrical Data Recording

Operating Measurements: Cooling

Cooling System Measurements

Recording key refrigerant pressures, temperatures, and superheat.

Air Temperature and Humidity Measurements

Refrigerant Safety Checks

Procedures for verifying refrigerant circuit safety controls.

Operating Measurements: Gas Heating

Gas Leak Check

Procedure to check for gas leaks in the unit piping.

Ventor Motor Operation Verification

Primary Safety Operation Verification

Gas Heating Manifold Pressure

Recording manifold pressure for different heat stages.

Supply Gas Pressure at Full Fire

Gas Heat Temperature Rise Check

Checking and recording the temperature rise during gas heat operation.

Operational Measurements: Staging Controls

Heating;Cooling Staging Control Verification

Steps to verify proper sequencing of heating and cooling stages.

Variable Frequency Drive Operation Verification

Final Inspection Checklist

Final checks before concluding the installation and start-up process.

Control Set Point Verification

Verifying all operational control set points are correctly configured.

Option Parameter Verification

Ensuring all installed options are correctly enabled in software.

Access Panel Security Check

York ZJ Series Specifications

General

Series	ZJ
Refrigerant	R-410A
Voltage Options	208/230V
Heating Capacity Range	24, 000 - 60, 000 BTU/H
Warranty	10-year limited warranty on compressor