York ZK Series - User Manual

R-410A
ZK SERIES W/SMART EQUIPMENT™
3 - 5 Ton
60 Hertz
5566228-BIM-A-0818
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
Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . . . . 48
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 49
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 49
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 50
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 50
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control Board Navigation Components . . . . . . . . . . . . . . . . . . . . 55
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
LIST OF TABLES
1 ZK-A3 thru -A5 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZK-A3 thru -A5 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8
4 ZK-A3 thru -A5 Unit Physical Dimensions . . . . . . . . . . . . . . . 11
5 ZK-A3 thru -A5 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 . . . . . . . . . . . . . . . 38
17 ZK-A3 thru -A5 Side Duct Application . . . . . . . . . . . . . . . . . . 40
18 ZK-A3 thru -A5 Bottom Duct Application. . . . . . . . . . . . . . . . 41
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 49
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 51
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 53
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 56
30 Cable for FC Buses and SA Buses in Order of Preference . 61
31 Flash Codes for the Gas Heat Ignition Control Board . . . . . 62
32 ZK-A3 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
33 ZK-A4 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
34 ZK-A5 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 ZK Component Location (ZK-A3 Shown) . . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZK-A3 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZK-A4 thru -A5 Physical Dimensions . . . . . . . . . . . . . . . . . . 10
10 ZK-A3 thru -A5 Unit Bottom Duct Openings . . . . . . . . . . . . . 12
11 ZK-A3 thru -A5 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13
12 ZK-A3 thru -A5 Unit Side Duct Openings . . . . . . . . . . . . . . . 13
13 ZK-A3 thru -A5 Unit Left/End Duct Opening . . . . . . . . . . . . . 14
14 ZK-A3 thru -A5 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZK-A3 thru -A5 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15
16 Side Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
17 Return Panel In Place For Side Duct Conversion . . . . . . . .16
18 Supply Panel In Place For Side Duct Conversion . . . . . . . .16
19 Save Side Panels For Economizer Hood Tops . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Typical Low Voltage Field Wiring . . . . . . . . . . . . . . . . . . . . . 19
23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 33
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
29 Reheat Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48
30 Cooling Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48
31 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
32 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . . 55
33 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . 55
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Summary

General Information and Safety

General

Details safety alert symbol, signal words DANGER, WARNING, CAUTION.

Safety Considerations

Details safety alert symbol, signal words DANGER, WARNING, CAUTION.

Installation

Installation Safety Information

Read instructions before installation, consider gas type, location, testing, and temporary use.

Location

Guidelines for selecting a suitable installation location for the units.

Unit Components and Options

Nomenclature

Explains the model number nomenclature and its components.

Compressors

Information about compressors designed for R-410A and their sensitivity to moisture.

Economizer

Details four types of free cooling options: dry bulb, single enthalpy, dual enthalpy, and auto.

Free Cooling

Details four types of free cooling options: dry bulb, single enthalpy, dual enthalpy, and auto.

Smoke Detectors

Specific limitations and operational details of duct smoke detectors.

Operation Sequences

Operation

Details the sequence of operations for cooling mode, including thermostat calls and component energization.

Cooling Sequence Of Operation

Details the sequence of operations for cooling mode, including thermostat calls and component energization.

Electric Heating Sequence Of Operations

Steps for single-stage electric heating operation.

Gas Heating Sequence Of Operations

Step-by-step operation for single-stage gas heating.

Troubleshooting and Start-Up

High-Pressure Limit Switch

How the UCB monitors and responds to high-pressure limit switch events.

Checking Gas Heat Input

How to determine the rate of gas flow for single-stage gas heat.

Start-Up (Cooling)

Checklist of items to verify before starting the cooling system.

Prestart Check List

Checklist of items to verify before starting the cooling system.

Measurements and Final Checks

OPERATING MEASUREMENTS - Air Flow

Procedures for measuring and recording air flow parameters.

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

Verifying proper operation of heating/cooling staging and variable frequency drive.

FINAL - INSPECTION

Final checks including setpoints, options, access panels, and backup files.

York ZK Series Specifications

General

Brand	York
Model	ZK Series
Category	Air Conditioner
Language	English