York ZS Series - User Manual

R-410A
ZS SERIES
6-1/2 - 12-1/2 Ton
60 Hertz
518676-BIM-C-0610
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP). . . . . . . . . . . . . . . . . . . . . . 36
Standard Economizer And Power Exhaust Set Point 
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 53
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54
Ignition Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 55
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . . . . . 61
Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LIST OF TABLES
1 ZS-06 thru -12 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZS-06 thru -12 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9
4 ZS-06 thru -12 Unit Physical Dimensions . . . . . . . . . . . . . . . 11
5 ZS-06 thru -12 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 ZS-06 thru -12 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 30
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 31
12 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 32
13 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 40
15 Airflow Performance - Side Duct Application . . . . . . . . . . . . . 42
16 Airflow Performance - Bottom Duct Application . . . . . . . . . . 44
17 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 46
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 46
20 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . . 48
21 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
22 Electric Heat Limit Setting 50” Cabinet . . . . . . . . . . . . . . . . . 53
23 Electric Heat Limit Setting 42” Cabinet . . . . . . . . . . . . . . . . . 54
24 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54
25 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 56
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
29 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 60
30 Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 62
32 VAV Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . 62
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 ZS Component Location (ZS-10 Shown) . . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZS-06 thru -10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZS-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZS-06 thru -12 Unit Bottom Duct Openings . . . . . . . . . . . . . 12
11 ZS-06 thru -12 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13
12 ZS-06 thru -10 Unit Side Duct Openings . . . . . . . . . . . . . . . 13
13 ZS-12 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . . 14
14 ZS-06 thru -12 Unit Left Duct Opening . . . . . . . . . . . . . . . . . 14
15 ZS-06 thru -12 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZS-06 thru -12 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . . 16
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect - Cooling Unit With/Without 
Electric Heat and All Units With VFD Option . . . . . . . . . . . . 18
22 Field Wiring Disconnect - Cooling Unit With 
Gas Heat Without VFD Option . . . . . . . . . . . . . . . . . . . . . . . 18
23 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . . 19
24 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . . . . 19
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
27 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
28 Honeywell Economizer Control W7212 . . . . . . . . . . . . . . . . 38
29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
30 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 40
31 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
32 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
33 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
35 Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . 63
36 Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
37 Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Summary

General

Safety Considerations

Important safety alerts and warnings for unit installation and operation.

Inspection

Reference

Approvals

Nomenclature

Installation

Installation Safety Information

Critical safety guidelines to follow before starting installation.

Preceding Installation

Steps to take before the main installation process begins.

Limitations

Location

Clearances

Required space around the unit for operation and service access.

Rigging And Handling

Guidelines for safely moving and lifting the unit.

Ductwork

Duct Covers

Condensate Drain

Information on the reversible condensate drain and its piping.

Compressors

Details on compressor specifications and R-410A refrigerant compatibility.

Filters

Power And Control Wiring

Power Wiring Detail

Specifics on wiring the unit for power supply and safety.

Thermostat Wiring

Optional Electric Heat

Optional Gas Heat

Gas Connection

Vent And Combustion Air

Options;Accessories

Smoke Detectors

Information on duct smoke detector limitations and installation.

Motorized Outdoor Damper

Details on the motorized outdoor damper option and its installation.

Economizer

Power Exhaust

Rain Hood

Optional Variable Air Volume (VAV)

Duct Static Pressure Transducer

VAV Control Board

Factory-installed VFD

Manual Bypass

Bas-ready VFD

Optional Hot Gas Bypass (HGBP)

Standard Economizer And Power Exhaust Set Point Adjustments

Enthalpy Set Point Adjustment

Indoor Air Quality AQ

Phasing

Blower Rotation

Belt Tension

CFM Static Pressure and Power-Altitude and Temperature Corrections

Drive Selection

Air Balance

Checking Air Quantity

Methods for measuring and balancing airflow within the system.

Supply Air Drive Adjustment

Operation

Cooling Sequence Of Operation

Step-by-step process of how the unit operates during cooling cycles.

Continuous Blower

Intermittent Blower

Optional VAV Start-up and Control

Economizer With Single Enthalpy Sensor

Economizer With Dual Enthalpy Sensors

Economizer With Optional VAV OR Intelli-Comfort Control

Cooling Operation Errors

High-Pressure Limit Switch

How the unit responds to high-pressure limit switch activation.

Low-Pressure Limit Switch

How the unit responds to low-pressure limit switch activation.

Freezestat

How the unit responds to freezestat activation during cooling.

Compressor Protection

Flash Codes

Reset

Electric Heating Sequence Of Operations

Two-stage heating

The sequence of operation for two-stage electric heating.

Electric Heat Operation Errors

How the unit handles errors related to electric heat operation.

Electric Heat Anticipator Setpoints

Gas Heating Sequence Of Operations

Gas Heating Operation Errors

Lock-Out

How the system enters a lockout state after multiple failures.

Temperature Limit

Unit response to high temperature limits during gas heating.

Flame Sense

How the flame sensing circuit operates and detects flame.

Start-Up (Cooling)

Prestart Check List

Checks to perform after installation before initial cooling operation.

Operating Instructions

Steps for operating the unit during the cooling season.

Start-Up (Gas Heat)

Pre-Start Check List

Checks to perform before starting the gas heat system.

Lighting The Main Burners

Checking Gas Heat Input

Manifold Gas Pressure Adjustment

Adjustment Of Temperature Rise

Troubleshooting

ZS Flash Codes

Unit Control Board Option Setup

Option Byte Setup

Configuring unit options via the control board's option byte settings.

Heat Delay Setup

Adjusting the heat delay settings on the control board.

Figure 35: Basic Troubleshooting Flowchart

Figure 36: Power On Flow Chart

Figure 37: Trip Failure Flow Chart

Cooling Troubleshooting Guide

Gas Heat Troubleshooting Guide

York ZS Series Specifications

General

Brand	York
Model	ZS Series
Category	Air Conditioner
Language	English