York ZF036 Installation Manual Download Page 5

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826081-XIM-C-0214

Johnson Controls Unitary Products

Renewal Parts

Contact your local York

parts distribution center for authorized

replacement parts.

Approvals

Design for use as follows:

For use as a cooling only unit, cooling unit with
supplemental electric heat or a forced air furnace.

For outdoor installation only.

For installation on combustible material.

For use with natural gas (convertible to LP with kit).

This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state, and national codes including, but not limited
to, building, electrical, and mechanical codes.

Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage.

This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.

Summary of Contents for ZF036

Page 1: ...Pressure Adjustment 36 Pilot Checkout 36 Burner Instructions 36 Burner Air Shutter Adjustment 37 Checking Gas Input 37 Adjustment Of Temperature Rise 37 Troubleshooting 38 Cooling Troubleshooting Guide 38 Gas Heat Troubleshooting Guide 39 Flash Code Troubleshooting 40 Symptomatic Troubleshooting 42 Unit Flash Codes 43 Fan On And Off Delays 43 Typical Wiring Diagrams 45 LIST OF TABLES 1 Control Wir...

Page 2: ... Front View 23 13 Unit With Economizer Rain Hood 24 14 Unit With Fixed Outdoor Air Motorized Damper Rain Hood 24 15 Unit Dimensions Rear View 25 16 Disconnect Blower Access Location 25 17 Belt Adjustment 30 18 Pressure Drop Across Coil 31 19 Gas Valve Piping 34 20 Typical Gas Valves 36 21 Proper Flame Adjustment 36 22 Typical Flame Appearance 37 23 Unit Control Board 44 24 Typical ZF036 076 Belt O...

Page 3: ...ving parts and electrical components installation and servicing of air conditioning equipment can be hazardous Only qualified trained ser vice personnel should install repair maintain or service this equipment Observe all precautions in the literature on labels and tags accompanying the equipment whenever working on air conditioning equipment Be sure to follow all other safety precautions that app...

Page 4: ...assistance or additional information consult a qualified installer service agency or the gas supplier This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system Gage sets hoses refrigerant containers and recovery systems must be designed to handle R 410A If you are unsure consult the equipment manufacturer Failure to use R 410A ...

Page 5: ...ombustible material 4 For use with natural gas convertible to LP with kit This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes Improper installation may create a condition where the operation of the product could cause personal injury or...

Page 6: ...tor AC Coil Guard AD Dirty Filter Switch AE Phase Monitor Coil Guard AF Phase Monitor Dirty Filter Switch AG Coil Guard Dirty Filter Switch AH Phase Monitor Coil Guard Dirty Filter Switch AS Bottom Drain Connection RC Coil Guard American Flag TA Technicoat Condenser Coil TJ Technicoat Evaporator Coil TS Technicoat Evaporator and Condenser Coil Additional Options Hinged Toolless Access Cabinet BA H...

Page 7: ...an Electrical Code CSA C22 1 2 Installation Codes CSA B149 1 3 Local plumbing and waste water codes and 4 Other applicable local codes Refer to unit application data found in this document After installation gas fired units must be adjusted to obtain a temperature rise within the range specified on the unit rating plate If components are to be added to a unit to meet local codes they are to be ins...

Page 8: ...n air in accordance with section 5 3 of Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 Latest Edition in U S A or Sections 7 2 7 3 or 7 4 of Gas Installation Codes CSA B149 1 in Canada Latest Edition and or applicable provisions of the local building codes Refer to Table 13 for clearances required for combustible construction servicing and proper unit operation LENGTH...

Page 9: ...ers must always be installed ahead of the evaporator coil and must be kept clean or replaced with same size and type Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shutdown Minimum filter area and required sizes are shown in Physical Data Table 8 Service Access The following removable panels provide access to all serviceable components Compressor comp...

Page 10: ...S CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 3 1 2 4 3 1 2 4 Second stage heating not required on single stage heating units Second stage cooling not required on single stage cooling units Jumper is required if there is no Smoke Detector circuit Jumper is required for any combination of R RC or RH 6 5 5 6 OCC is an output from the thermostat to indicate the Occupied condit...

Page 11: ...e unit must be replaced replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire Electrical line must be sized properly to carry the load Use copper conductors only Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused Refer to the Typical Field Wiring Figure 3 and to the appropriate unit ...

Page 12: ... specific gravity of the gas and the length of run National Fuel Gas Code Z223 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada should be followed in all cases unless superseded by local codes or gas utility requirements Refer to the Pipe Sizing Table 4 The heating value of the gas may differ with locality The value should be checked with the local gas utility NOTE There may b...

Page 13: ...as pressure to the mains Check all joints for leaks with soap solution or other material suitable for the purpose NEVER USE A FLAME 6 The furnace and its individual manual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 48kPa 7 The furnace must be isolated from the gas supply piping system by...

Page 14: ...top flange of this hood slips in under the top of the access panel opening when installing Refer to Vent and Combustion Air Hood Figure 6 The vent hood is installed by inserting the top flange of the hood into the slotted opening in the access panel and securing in place The products of combustion are discharged horizontally through this screened hooded vent openings on the gas heat access panel O...

Page 15: ...no power exhaust option adjust the Exhaust Air Adjustment Screw fully clockwise With power exhaust option each building pressurization requirement will be different The point at which the power exhaust comes on is determined by the economizer damper position Percent Open The Exhaust Air Adjustment Screw should be set at the Percent Open of the economizer damper at which the power exhaust is needed...

Page 16: ...826081 XIM C 0214 16 Johnson Controls Unitary Products Figure 7 Enthalpy Setpoint Adjustment ...

Page 17: ...1 Exhaust Air Adjustment Screw Exhaust Air LED Damper Min Position Screw Indoor Air Quality Max Adjustment Screw Indoor Air Quality LED Indoor Air Quality Min Adjustment Screw Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw 826081 XIM C 0214 Johnson Controls Unitary Products 17 Figure 8 Honeywell Economizer Control W7212 ...

Page 18: ...X Y LEFT FRONT Table 6 ZF036 076 Metric Size Tons Model Weight kg Center of Gravity mm 4 point Load Location kg 6 point Load Location kg Shipping Operating X Y A B C D A B C D E F 036 3 0 ZF036 228 225 1005 8 492 8 50 3 46 7 61 7 61 7 34 0 32 7 30 8 40 4 42 6 44 9 048 4 0 ZF048 238 236 995 7 480 1 52 2 47 2 64 9 71 7 35 4 33 1 31 3 42 6 45 5 48 5 060 5 0 ZF060 251 249 995 7 480 1 54 9 49 9 68 5 75...

Page 19: ...re Rise Range ºF 15 45 45 75 25 70 45 75 25 55 35 75 25 55 30 75 Gas Limit Setting ºF Direct Drive 240 170 210 165 Gas Limit Setting ºF Belt Drive 210 210 210 210 Gas piping connecting in 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 DIMENSIONS inches Length 82 1 4 82 1 4 82 1 4 82 1 4 Width 44 7 8 44 7 8 44 7 8 44 7 8 Height 32 5 8 32 5 8 32 5 8 32 5 8 OPERATING WT lbs 468 541 569 640 COMPRESSORS Type Recip Re...

Page 20: ... EVAP FAN DATA Quantity 1 1 Fan Size Inch 12 x 10 12 x 11 Type Centrifugal Centrifugal Motor Sheave 1VL44 IVM50 Blower Sheave AK54 AK56 Belt A35 A36 Motor HP each 1 1 2 1 1 2 RPM 1450 1450 Frame size 56 56 DIRECT DRIVE EVAP FAN DATA Quantity 1 1 Fan Size Inch 12 x 10 12 x 10 Type Centrifugal Centrifugal Motor HP each 1 2 1 RPM 1050 1050 FILTERS 15 x 20 x 1 or 2 2 2 2 2 14 x 25 x 1 or 2 1 1 1 1 Tab...

Page 21: ... 1 3 4 2 None 14 4 20 2CE04510746 4 3 6 5 14 4 20 2CE04511046 6 3 9 6 17 3 20 2CE04511546 8 5 12 9 21 4 25 2CE04512046 12 2 18 5 28 5 30 415 3 50 7 1 54 11 1 1 3 4 2 None 14 4 20 2CE04511046 5 1 7 1 14 4 20 2CE04511546 7 5 10 4 18 3 20 2CE04512046 10 2 14 2 23 25 2CE04512546 14 6 20 3 30 7 35 ZF060 380 3 50 8 0 67 12 5 1 3 2 7 None 14 20 2CE04510746 4 3 6 5 14 20 2CE04511046 6 3 9 6 15 3 20 2CE045...

Page 22: ...GE kW CAP MULTIPLIER 380 380 0 627 415 415 0 75 POWER SUPPLY VOLTAGE MIN MAX 380 415 3 50 342 456 826081 XIM C 0214 22 Johnson Controls Unitary Products Table 10 Electric Heat Correction Factors Table 11 Voltage Limitations ...

Page 23: ...ions 3 6 3 Ton Cooling Gas Heat Front View 829 325 8 1140 447 8 64 21 2 213 83 8 292 111 2 445 171 2 445 171 2 181 77 8 171 63 4 206 81 8 137 53 8 2089 821 4 165 61 2 mm inch 829 325 8 1140 447 8 64 21 2 213 83 8 292 111 2 445 171 2 445 171 2 181 77 8 171 63 4 206 81 8 137 53 8 2089 821 4 165 61 2 178 7 111 43 8 165 61 2 819 321 4 819 32 1 4 mm inch ...

Page 24: ...conomizer Rainhood Figure 14 Unit With Fixed Outdoor Air Motorized Damper Rainhood DETAIL A 699 271 2 699 271 2 41 15 8 260 101 4 1140 447 8 502 193 4 mm inch DETAIL B 454 177 8 184 71 4 699 271 2 485 191 8 1140 447 8 305 12 419 161 2 mm inch 260 101 4 89 31 2 210 81 4 111 43 8 ...

Page 25: ...Side Cond Coil 610 24 0 Below Unit1 1 Units may be installed on combustible floors made from wood or class A B or C roof covering material 0 Above Unit2 2 Units must be installed outdoors Overhanging struc tures or shrubs should not obstruct condenser air dis charge outlet 1829 72 0 For Condenser Air Discharge Figure 15 Unit Dimensions Rear View mm inch 445 171 2 445 171 2 165 61 2 292 111 2 76 3 ...

Page 26: ...LOW 1681 760 1640 738 1604 715 1541 695 1490 670 CFM WATTS CFM WATTS CFM WATTS CFM WATTS HI 1430 725 1360 700 1280 680 1180 655 MED 1324 650 1260 630 1185 610 1100 590 LOW 1246 605 1185 590 1110 570 1020 545 HI 1635 820 1544 790 1419 765 1300 740 MED 1508 705 1407 675 1306 645 1195 625 LOW 1416 645 1337 620 1230 595 1120 575 3 1 4 1 AVAILABLE EXTERNAL STATIC PRESSURE Pa M3 S 149 50 74 99 124 UNIT ...

Page 27: ...160 1002 1170 1022 1190 1044 1250 1066 1350 1090 1410 1117 1440 2100 930 1060 957 1070 983 1080 1010 1100 1039 1160 1064 1260 1092 1340 2000 877 950 908 975 941 1000 976 1020 1009 1050 1040 1100 1070 1225 1900 894 885 940 940 980 980 1014 1020 1047 1095 1800 855 815 903 860 950 905 988 940 1022 970 1700 884 815 925 850 964 880 1001 910 1600 864 770 908 805 948 835 987 870 1500 882 740 926 780 965 ...

Page 28: ... 1102 1850 1131 1940 1160 2025 1190 2075 2600 985 1425 1015 1475 1045 1540 1075 1630 1103 1715 1135 1760 1163 1825 2400 930 1240 958 1300 990 1350 1020 1400 1051 1430 1081 1490 1111 1600 2200 905 1070 933 1160 965 1210 997 1250 1028 1285 1060 1325 2000 919 1025 950 1100 982 1130 1014 1160 1800 909 925 939 1005 968 1030 RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS 3200 3000...

Page 29: ...during full economizer operation 2 Add these resistance values to the available static resistance values on SUPPLY AIR BLOWER PERFORMANCE Tables Phasing YORK MODEL ZF units are properly phased at the factory Check for proper compressor rotation If the blower or compressors rotate in the wrong direction at start up the electrical connection to the unit is misphased Change the incoming line connecti...

Page 30: ...Remove the two 8 mm 5 16 dot plugs from the blower motor and the filter access panels shown in Figure 16 2 Insert at least 200 mm 8 of 6 mm 1 4 tubing into each of these holes for sufficient penetration into the air flow on both sides of the indoor coil NOTE The tubes must be inserted and held in a position perpendicular to the air flow so that velocity pressure will not affect the static pressure...

Page 31: ...mpressor has been completed After the compressor de energizes the blower is stopped following the elapse of the fan off delay for cooling To be available a compressor must not be locked out due to a high or low pressure switch or freezestat trip and the anti short cycle delay ASCD must have elapsed Economizer With Single Enthalpy Sensor When the room thermostat calls for cooling the low voltage co...

Page 32: ...usion of the ASCD the UCB will re energize the compressor Should a freezestat open three times within two hours of operation the UCB will lock out the compressor and flash a code see Table 24 Low Ambient Cooling To determine when to operate in low ambient mode the UCB has a pair of terminals connected to a temperature activated switch set at 45ºF When the low ambient switch is closed and the therm...

Page 33: ...it Control Setting Table 19 It resets automatically The limit switch operates when a high temperature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower Reset Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature This resets any flash codes Heat Anticipator Setpoints HEATER KW VOLTAGE S...

Page 34: ...ill exists the ICB will start the ignition sequence over and the UCB will de energize the blower for 45 seconds However the auxiliary limit is in series with the primary limit and it takes first control If the excessive heat has been high enough to cause the auxiliary limit AUX to open then the ICB will flash the primary limit code but the furnace will not retry ignition during the same call for h...

Page 35: ...he electrical supply voltage being supplied Be sure that it is the same as listed on the unit nameplate 2 Set the room thermostat to the off position 3 Turn unit electrical power on 4 Set the room thermostat fan switch to on 5 Check indoor blower rotation If blower rotation is in the wrong direction Refer to Phasing Section in general information section Check blower drive belt tension 6 Check the...

Page 36: ... B U L B C A R R Y O V E R T U B E F L A M E S E N S O R B U L B B U R N E R A S S E M B L Y B R A C K E T Small adjustments to the high fire gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve Adjust as follows 1 Remove the cap on the regulator It s located next to the push on electrical terminals 2 To decrease the gas pressure turn the adjusting scre...

Page 37: ...your particular locality contact your gas company for this information it varies widely from city to city Adjustment Of Temperature Rise CFM Btuh Input x 0 8 108 x F Temp Rise o The temperature rise or temperature difference between the return air and the heated air from the furnace must lie within the range shown on the rating plate and the data in the Gas Heat Application Table 3 After the tempe...

Page 38: ...G terminal is connected to the G terminal of the UCB and for loose wiring 10 If the thermostat and UCB are properly wired replace the UCB On a call for cooling the supply air blower motor is operating but the compressor is not the room thermostat fan switch is in the AUTO position 1 If installed check the position of the economizer blades If the blades are open the economizer is providing free coo...

Page 39: ...Y1 ECON terminal 13 For units with economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug a poor connection between the UCB and economizer Mate N Lock plugs loose wiring from the Mate N Lock plug to the economizer back to the Mate N Lock plug and from the...

Page 40: ...ve ICB LED If it now flashes the heartbeat then the fault was a bad connection between the harness connector and the ICB connector or a broken wire exists in the harness With the harness connected to the ICB gently move the wires in the harness while observing the ICB LED If heartbeat is steady then verify proper operation of the furnace If the ICB does not flash the heartbeat then gently move the...

Page 41: ... manual reset type If either one opens then the ICB removes power to the gas valve and the UCB energizes the indoor blower until the primary limit automatically resets or the auxiliary limit is manually reset Verify adequate air flow through the furnace If air flow is nonexistent or weak then troubleshoot and repair the conditioned space air circulation system as necessary Reset the auxiliary limi...

Page 42: ...ce the motor 6 If 24 volts is not present at M2 check that 24 volts is present at the supply air blower motor terminal on the UCB If 24 volts is present at the UCB terminal check for loose wiring between the UCB and M2 7 If 24 volts is not present at the UCB supply air blower motor terminal check for 24 volts from the room thermostat If 24 volts is not present from the room thermostat check for th...

Page 43: ...er orifices for obstruction and alignment Removal procedure is described in BURNER INSTRUCTIONS on page page 36 Clean or replace burner orifices and burners as needed Unit Flash Codes Various flash codes are utilized by the unit control board UCB and the ignition control board ICB to aid in troubleshooting Flash codes are distinguished by the short on and off cycle used approximately 200ms on and ...

Page 44: ...w Voltage 14 Flashes EEPROM Storage Failure Control Failure OFF No Power or Control Failure Flash Code Description Heart Beat Normal Operation 1 Flash Not Applicable 2 Flashes Pressure Centrifugal Switch Open with Inducer On 3 Flashes Pressure Centrifugal Switch Closed with Inducer Off 4 Flashes Not Applicable 5 Flashes Lock Out From Too Many Flame Losses 6 Flashes High Temperature Switch Open Pri...

Page 45: ...826081 XIM C 0214 Johnson Controls Unitary Products 45 Figure 24 Typical ZF036 076 Belt Or Direct Drive With Electric Heat Control Circuit 380 415V Diagram ...

Page 46: ...826081 XIM C 0214 46 Johnson Controls Unitary Products Figure 25 Typical ZF036 048 Direct Drive With Gas Or Electric Heat Power Circuit 380 415V Diagram ...

Page 47: ...826081 XIM C 0214 Johnson Controls Unitary Products 47 Figure 26 Typical ZF060 076 Belt Drive With Gas Or Electric Heat Power Circuit 380 415V Diagram ...

Page 48: ...C 0214 Copyright 2014 by Johnson Controls Inc All rights reserved Supersedes 826081 XIM B 0412 York International Corporation 5005 York Drive Norman OK 73069 Figure 27 Typical ZF036 076 Belt Drive Or Direct Drive With Gas Heat Control Circuit 380 415 3 50 Diagram ...

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